Importance of following safety guidelines for operating Gantry Cranes

You can operate the gantry crane efficiently and prevent accidents by following safety regulations and operating manuals. You can save both your own life and the life of a coworker thanks to safety regulations. If you want to acquire a portable gantry crane, you should check to see if the manufacturer complies with ANSI and OSHA requirements. This is because if you have to manufacture gantry cranes, you must do so in accordance with OSHA regulations.
The lifting machine instructions can help you operate the crane more effectively and learn more about the gantry crane machine, while safety regulations can help you prevent minor errors and protect you and your coworkers from mishaps. The most frequent causes of accidents are inexperienced and unprofessional operators, objects falling from cranes, overloading, electric hazards, and negligent maintenance.

Safety Standard To Follow While Operating Portable Gantry Cranes

You must abide by the safety regulations listed below if you use portable gantry cranes in your line of work. Doing so will help you prevent accidents from occurring.

• Verify the hoist or gantry crane. It must not be marked as broken or unusable.
• Examine the wire rope of the gantry crane for any tearing or damage.
• Verify the gantry cranes’ safety labels.
• Never go underneath a gantry crane that is loaded.
• Set up alarms all around the crane’s area of operation.
• Steer clear of abrupt acceleration and deceleration.
• When the weight is suspended, try to avoid jerking the gantry crane hoist excessively.
• Regularly schedule periodic checks for every quarter or half-year.
• Any combustible liquid should be removed from the neighbouring crane.
• Never fill the crane with more weight than it can support.
• The crane may only be operated by qualified persons.
• In the vicinity of the crane and its runway, look out for tripping hazards and liquid leaks.

Do’s and Don’ts of Gantry Crane operation

Do’s

• Testing your gantry’s condition before using it is always a good idea. Inadequate brakes or malfunctioning parking jacks, the accumulation of trash on the runway, broken welds, and loosened fasteners are a few examples of warning signs you might look out for.
• In order to prevent tipping, make sure the ground is level.
• Make sure the load that has to be hoisted is directly beneath the gantry.
• Before beginning the lifting procedure, make sure the wheel locks and brakes are securely locked.

Don’ts

• Moving a loaded gantry is prohibited.
• Keep the burden from swinging.
• Never ever use a vehicle to pull a gantry.
• Avoid going underneath a loaded gantry.
• Keep all other objects away from the gantry.

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Gantry Crane Materials

Since the 1870s, steel has been used in lifting applications. Iron constructions predominated up until this point. Contrarily, aluminium is a very recent addition to the market. Much more recently, aluminium lifting equipment has proliferated across the sector. When used for industrial lifting, both aluminium and steel offer benefits and drawbacks. This article focuses on gantry cranes in particular, comparing the two material options and providing guidance for users and specifiers.

Aluminium vs Steel

Strength to weight ratio

Steel can weigh 2.5–3 times more than aluminium for gantry cranes of similar size and load rating. Aluminium gantries have a lower total weight than steel gantries and are simpler to operate physically due to this substantial difference in strength to weight ratio. The simplicity of tool assembly, use, and disassembly is crucial in a business environment where worker health and safety have never been more vital. Aluminium gantries provide substantial economic advantages since they are essentially movable.

Resistance to corrosion

Any finish applied to a steel surface eventually erodes, peels, chips, or cracks. This will leave a surface that is exposed and vulnerable to rust. If inspections are not carried out frequently, this significantly reduces the equipment’s lifespan and may be dangerous. The similar problem does not arise with aluminium, especially when it has been anodized (artificially aged).
According to the (British Standard), low-carbon steel can lose between 80 and 200 microns of material thickness annually in areas with very high corrosion (Category 5 of 6). The aluminium construction will warrant a lower maintenance cost over the course of the product’s life because surfaces won’t need to be painted over or treated on a regular basis.

Deflection

Aluminium gantries have a marked tendency to deflect. The material, but also the structure’s design, can have an impact on the length to deflection ratio. An aluminium beam can bend but will straighten up once the load is lifted, but a steel beam will appear to remain relatively level under strain. When the aluminium gantry’s load limit is exceeded, the beam will gradually continue to bend more and more until the material eventually reaches its yield point. This is known as soft failure or benign failure and happens when this happens. Steel does not flex as much under stress as aluminium does; instead, it maintains a reasonably flat and stiff posture.

Strength of materials

Steel unquestionably has the advantage in overall strength, despite aluminium’s advantage in strength to weight ratio. Steel gantries come in capacities ranging from 0.5t to over 100t. The top aluminium gantries in the world can support up to 5 tonnes. Additionally, steel gantries come in much bigger height and beam length configurations. Although the longest aluminium beam length is just about 30 feet, it is not uncommon to encounter steel gantries with 100 foot beams.

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Overview of Gantry and Jib Cranes and Their Applications

A gantry crane is a type of overhead crane that utilizes two side frames that span an area and are joined together by longitudinal beams. The trolley and hoist move along the beams, allowing them to lift and transport materials across vast areas. Gantry cranes can be used indoors and outdoors, depending on the size and design of the structure. They are commonly used in construction, manufacturing, shipping, port operations, rail yards, engineering workshops, maintenance facilities, and storage warehouses.

Jib cranes are overhead cranes that use either a fixed or cantilevered support arm to lift objects. This type of crane is smaller than other overhead cranes but offers more flexibility when moving materials up and down. Jib cranes are often used in industrial and manufacturing settings, providing a great range of movement in tight spaces. They can be used for light to heavy loads, depending on the size and design of the crane.

The difference in design

The primary distinction between jib cranes and gantry cranes is in their construction. A gantry crane is characterized by a horizontal I-beam that spans the distance between two points of end or support. These terminals typically have wheels so that the crane itself or the goods moved by the crane can be transferred to new places. A jib crane, on the other hand, is controlled by a single operator. As a rule, you’ll find it mounted to the floor or a wall. In addition, it can be used as a mobile crane.

The difference in movement

The gantry crane, comprised of a chain house and a trolley, moves loads along the I-beam’s horizontal plane. The jib crane is also helpful for this purpose. However, portability is required to serve the same purpose as a gantry crane. If the jib crane is installed underground, working distances will be reduced.

Factors to Consider While Buying Gantry Crane

1. Capacity: It is essential to consider the capacity of a gantry crane before making the purchase. The power should be determined based on the weight and size of the material or object that needs to be lifted by the crane.
2. Application: Similarly, it is necessary to determine the application for which the gantry crane will be used. Different types of cranes are available in the market with other features and specifications, so it’s essential to select one depending on its application.
3. Mobility: Most cranes today come with wheels and castors for easy mobility; however, some models do not have this feature and require additional components like hoists to move around. It is thus essential to check whether the model you are buying is mobile.
4. Price: Price is another crucial factor when purchasing a gantry crane. Different models have different prices, so selecting one within your budget is essential. It’s also possible to find used gantry cranes, which can be purchased much lower than new ones.
5. Maintenance: Regular maintenance is necessary for all types of machines, including gantry cranes, to ensure they remain safe and efficient during operation. Ensure you check the manufacturer’s maintenance procedures before making the purchase.
6. Safety features: Gantry cranes should have certain safety features such as overload protection, emergency stop, and other similar features. Ensuring that the model you buy has these safety features is essential.
7. Warranty: Most manufacturers offer warranties for their gantry cranes, so checking this before purchasing is essential. This will ensure that the manufacturer will cover any repair or replacement costs in case of any defect or malfunctioning of the crane.

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For large fabrication applications or in particular types of outdoor yards, such as rail yards, shipping and container yards, steel yards, and scrap yards, full gantry or semi-gantry cranes are frequently used.

They’re also highly well-liked in locations where they’re creating and curing slab concrete for precast and cement applications. Forklift trucks and other types of motorised traffic can work on them and pass through underneath thanks to their design, which also permits outdoor use.

Portable gantry cranes are typically used to lift and stabilise objects while they are being repaired, built, or assembled. Although the gantry itself can be moved about to operate on other pieces of machinery or equipment, the load need not always be transported across the facility.

A portable gantry system may also be more adaptable than a workstation crane or jib crane. A jib crane normally needs to be erected atop a foundation made of poured concrete, and once it is, it is there for good. As your firm expands and you start organising and setting out warehouse space, a smaller portable gantry crane that can be moved around your facility may do the same type of work as a jib crane.

Setting up the gantry

Any of the gantry choices should ideally be assembled by two individuals for added security. The steps goes as follows –

The long or short insert of your choosing is already in place within the A-frame and secured in place with a spring-loaded set pin when Gantry legs are supplied.

Additionally, the gantries are provided with the top plate already attached to the beam, enabling you to attach your beam to your gantry legs and change the width using Lindaptor clamps.

Gather all the components in the designated area once your gantry arrives on site, then just attach the top plate on one side of the beam to one of the gantry leg inserts before inserting the set pin to lock it in place.

Together with a partner, elevate the first leg and beam while the other person lifts the second gantry leg vertically. To lock in place, align the top plate with the insert, make sure it is in place, and then insert the set pin.

Install your beam clamp, trolley, and hoist, or, in some cases, a monorail beam, now that the gantry is at its lowest assembled height, so you won’t have to battle with them when they’re at operational height.

Next, attach the supplied come-a-longs to the bottom of the insert and the side of each gantry leg. Working in unison with your partner, retract the spring-loaded set pin and raise the gantry to the required height, making sure the beam stays level the entire time.

Release the set pins once the desired height has been attained, and your gantry is ready for use.

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Three primary parts are typically used in the construction of gantry cranes: an I-beam or wide-flange beam, two support legs, and an A-frame framework. Adding caster assemblies to the ends of the gantry legs gives the structure added mobility and makes it possible to move the gantry quickly from one place to another. Gantry cranes are a great choice for maintenance and repair tasks both inside and outside of the facility since they can hold the load without being permanently mounted to building supports or foundations.

The appropriate gantry crane for your application depends on the environment where the crane will be utilised, even though maintenance and repair applications differ depending on each individual operation. For quick maintenance and repairs, gantry cranes that will only be used indoors are portable and may be moved almost anyplace in your facilities. Nylacron casters, which are frequently used as a more affordable alternative to motorised travel, can also be installed on indoor gantry cranes. These cranes normally use polyurethane caster assemblies but can also be track installed for manual or powered travel over a fixed path.

Portable or relocatable gantry cranes are frequently the more ergonomic choice because the majority of maintenance and repair applications do not follow the same exact set path.

Engine or Electrical Maintenance and Repair

A movable steel gantry crane is the ideal choice for businesses that undertake equipment maintenance and repairs on vehicles and machines. Workers in these facilities frequently have to take out bulky parts from inside a car, including the engine or transmission. Lifting parts from larger vehicles without a material handling solution is quite challenging, whether the vehicle is an automobile, rail car, or transit vehicle. For the sectors of engine or electrical maintenance and repair, flexibility and mobility are essential. Height, length, and tread width can all be altered on adjustable gantry cranes.

Gantries’ sturdy construction enables the I-beam to self-center over the weight. The gantry crane may reach into machines using this cantilever and lift whatever is necessary. 

HVAC Maintenance and Repair

Using a lifting mechanism that is both extremely mobile and lightweight is often necessary for HVAC applications. Steel gantry cranes can be moved around a building without much difficulty, although they are difficult to load and unload from a service vehicle and to move to a roof. An aluminium gantry crane is the ideal choice for these applications. Gantry cranes made of aluminium are simple to load into a service van, unload, and move to any location that is needed. The aluminium gantry crane is simple to assemble by two employees in a short amount of time. Aluminum gantry cranes are a great material handling option for employees who install, repair, or service HVAC equipment on rooftops or other remote places since they can lift up to 3 tonnes. 

Aluminum gantry cranes are also versatile enough to lift on uneven terrain or operate in confined locations because they have changeable heights and spans. Additionally, pneumatic tyres can be added to aluminium gantry cranes, enabling them to be moved with ease outside and on almost any rooftop surface.

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Gantry cranes are supremely powerful with lifting capacity of up to several hundred tons. They offer superior performance and are among the most widely used rail cranes. Let’s understand the components and working of a gantry crane well. 

Components of the gantry crane operating system 

Gantry cranes are overhead cranes and can have double or single girders. The crane is supported by freestanding vertical pillars which move on a rail track. 

The components of the crane include the riving engine with breaks. There is a rail track or wheels for the freestanding legs to move. The vertical pillars not just offer support but also complete the entire system in such a way that the crane stands firmly. 

So, the main components include the drive unit which handles the load, the support unit that offers support to the drive unit and makes the movement possible, the track on which the train runs, and the device. 

Working principle of the gantry crane 

A coupling and a reducer connect the motor of the crane for it to start. The reducer has a shaft which starts rotating at low speed to bring the wire rope and the hook together. As soon as the motor starts, the movements get transferred to the reel which makes it move in clockwise and anticlockwise directions. With the movement, the wire rope gets rolled in and out, making it possible to lift or lower the load. 

The working of the gantry crane depends on the transformation of movement initiated by the monster into lifting and lowering of the load. If there is any sudden power cut, the operator applies breaks and the load stops at a specified position. Also, when the load reaches its limit position, the hook’s movement is automatically stopped as the limiter is touched. 

Usage of gantry cranes 

Gantry cranes are of many types and all of them serve different purposes. Depending on the available space, load requirements and other factors, different types of gantry cranes are used in different work spaces. Here are some of the types of gantry cranes: 

• Full gantry cranes 
• Semi gantry cranes 
• Adjustable gantry crane 
• Portable gantry crane

The full and semi gantry cranes are used in industries where heavy products need to be handled. The industries such as shipping and container yards, rail yards, scrap yards, steel yards, etc. The cranes are designed to work well in outdoor applications. These are large cranes and the trucks and other traffic can pass underneath them making it possible to work outside without worrying about space blockage. 

Portable gantry cranes are also quite useful. These offer greater flexibility than jib cranes and can function well as a workstation crane. The crane needs to be installed into a concrete foundation and once you are done, you have a permanent setup. The concrete set up is sturdy and lasts quite long. 
If you are thinking of buying a crane for your business, buying one from reputed gantry crane manufacturers in India is the way to go. If you are yet to find the right manufacturer who not only provides you with various options, but also offers guidance, you have reached the right place. Let our experts know about your doubts and choose the right fit for you.

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Overhead cranes as discussed above come very handy to the material handling industries and there are different specifications based on which they operate. In this article, we will be seeing some important specifications of overhead cranes which everybody must know

Overhead Crane Capacity

Load is an important criterion to assess the crane’s operating ability since it relates to the crane’s ability to lift a weight, which should include the quality of the sling and iron pole or container. EOT Crane manufacturers commonly refer to it as the rated weight and is denoted by the letter “Q.” The weight – beginning unit was formerly designated as “t,” but is now designated as “kN.” The weight of the crane fluctuates as the operating range of the crane changes. As a result, the rated weight includes the maximum weight as well as the maximum lifting weight.

Working Class

The horizontal distance between a crane’s central axis and the centre line of a hook under the rated weight is referred to as the working range. The radius of gyration or the radius of work are two terms used to describe it. The symbol for it is “R,” and the unit is “m.” The working range is the crane’s working range while it is not shifting.

Lifting Torque

The lifting moment is calculated by multiplying the crane’s lifting weight by its amplitude. The t*m unit of lifting torque was previously used. It is now written as kN*m. It is a crane’s total lifting capacity characteristic that can correctly and thoroughly depict the crane’s lifting capacity. Because the tower crane must operate over a wide range, the model’s key parameter is the lifting torque. The lifting torque of a tower crane generally refers to the greatest amplitude lifting moment.

Crane Lifting Height

The lifting height is the distance from the ground to the hook and the centre of the hook, and the rated lifting height is the calibration value of its parameters. From the centre of the hook to the ground, the rated lifting height refers to the rise of the hook to the maximum limit of the complete weight. The lower depth of the ground below the earth is termed the lower depth when the hook has to be hoisted below the ground, and the total lifting height is the sum of the lifting height and the lower depth.

Crane Working Speed

The crane’s operating speed comprises lifting, amplitude altering, turning, and walking speeds. The unit for the rise and rise speed of the lifting speed is “m/min,” which refers to the rising or lowering speed of the lifting hook. The crane’s lifting speed is tied to the hoisting mechanism’s lifting speed, which is related to the hook pulley group’s ratio. The single rope is twice as quick as the double rope; the rope is twice as fast as the rope. In general, the lifting speed parameter should be specified, as well as the number of ropes.

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Cranes, as previously stated, are the most significant element of any industry, which is why they must be properly maintained and cared for in order to extend their lives and boost their durability. It is critical that your crane be serviced on a regular basis if you want to get the most out of it. In this article, we’ll go over everything you need to know about crane health checkup.

Importance of crane health checkup

You will never have to worry about your crane’s performance as long as it is serviced on a regular basis. All the gantry crane manufacturers in India will recommend that a specific preventative maintenance programme should be designed and implemented across all industries that use cranes, and that the manufacturer’s suggestions should be included in the programme. Periodic inspection alerts you to and assists you in monitoring any symptoms of wear and tear in the system, as well as allowing you to arrange repair prior to a breakdown to save unneeded downtime. It is possible to save a significant amount of money by preventing downtime, which is a critical aspect for any company.

Frequent inspection and periodic inspection are the two most common forms of inspection. Frequent inspections take place every day to every month, whereas periodic inspections take place once a month to once a year. Users, on the other hand, choose different sorts of inspection programmes depending on the crane’s use and age.

Phases of crane health checkup

The health checkup of the inspection of an overhead crane must be carried out in 4 phases and all of them are discussed in brief below

• Initial Inspection

After installing the new crane or the hoist, initial inspection, as the name suggests, is the first phase of the inspection which is carried out visually to check if everything related to hoisting and installation is perfect. Initial inspection is carried out even after modification, repair or reinstallation of cranes. An authorized appointed person is allowed to do the initial phase of inspection.

• Functional Test Inspection

Functional test or inspection involves the testing of every functionalities of the crane which is conducted after every shift. In this inspection, each and every part of the air and hydraulic system such as tanks, valves, drain pumps etc are checked and inspected thoroughly for any leakage.

• Frequent Inspection

Based on the usage of your carne, frequent inspections are carried out which mainly focuses hoist brake, wire rope, load chain etc and many abnormalities are found out by even listening to any abnormal sounds. Frequent inspection must include all the parameters included in the functional test inspection apart from the ones listed earlier.

• Periodic Inspection

Periodic inspections are carried out for the cranes with normal to heavy usage and the period for this inspection is yearly. If the crane you are using has not been in use for a month but has been used within 6 months, it is recommended that a periodic inspection must be carried out before its next usage.

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