Overhead Cranes for Silo Manufacturing: Applications & Capacity

After rolling, steel plates become curved sections or cylindrical shell components. These are used to manufacture the main bodies of storage silos.

Typical characteristics:

• Shell diameter: 3–12 m
• Individual shell section height: 1.5–3 m
• Plate thickness: commonly 6–12 mm in illustrative examples, but project-specific
• Estimated section weight: approximately 2–15 ton or more

The actual weight depends on diameter, height, plate thickness, reinforcements, stiffeners, and attached components.

Suitable lifting equipment:

• Spreader beams
• Multi-point lifting beams
• Customized shell lifting frames
• Double-girder overhead cranes for heavier assemblies

Large cylindrical sections require particular attention to lifting-point positions, load balance, and shell deformation.

Hopper and cone sections are used in silo discharge systems and material handling structures. Their conical geometry makes lifting and positioning more complex than handling flat plates.

Typical characteristics:

• Diameter: 2–6 m
• Estimated weight: 2–10 ton
• Dimensions and weight vary with cone angle, plate thickness, reinforcement, and design.

Suitable lifting equipment:

• Customized spreader beams
• Lifting frames
• Multi-point lifting arrangements

The lifting device should be designed around the component's geometry and approved lifting points.

Silo roofs may include steel panels, beams, trusses, support frames, and connecting structures.

Typical characteristics:

• Component length: 3–12 m
• Estimated individual component weight: 1–8 ton

Suitable lifting equipment:

• Standard crane hooks
• Lifting beams
• Spreader beams
• Customized structural lifting frames

For long structural components, multiple lifting points may be required to maintain balance and prevent excessive deflection.

Some factories manufacture large silo sections or complete assemblies before transporting them to the installation site.

Typical characteristics:

• Component diameter: 3–12 m or larger
• Estimated weight: 5–35 ton or more
• Dimensions and weight depend on the silo design and fabrication method.

Suitable lifting equipment:

• Double-girder overhead cranes
• Engineered spreader beams
• Customized lifting frames

For exceptionally large components, the manufacturer should evaluate whether one crane or a coordinated multi-crane lifting arrangement is appropriate.

Note: These figures are preliminary planning references rather than standardized component specifications. Actual weights must be calculated from drawings, material thickness, reinforcements, and the complete component configuration.

Main operations: Loading steel plates onto CNC plasma or laser cutting machines, unloading cut sections, and transferring prepared components to the next production stage.

Typical loads handled:

• Full-size steel plates: approximately 0.5–3 ton.
• Cut plate sections: approximately 0.2–2 ton.
• Prepared steel components: approximately 0.5–3 ton.

Recommended crane configuration:

• Crane capacity: 3–5 ton.
• Crane type: Single-girder overhead crane for many general plate-handling applications.
• Lifting equipment: Plate clamps, vacuum lifters where suitable, or horizontal lifting beams.
• Quantity: Typically 1 crane per production bay; additional cranes may be needed for separate cutting lines or larger workshops.

Main operations: Feeding flat steel plates into rolling machines, removing rolled plates, handling curved sections, and transferring cylindrical shell components to welding stations.

Typical loads handled:

• Steel plates before rolling: approximately 1–5 ton.
• Rolled plate sections: approximately 1–8 ton.
• Cylindrical shell sections: approximately 2–15 ton or more, depending on diameter, height, and plate thickness.

Recommended crane configuration:

• Crane capacity: 5–20 ton.
• Crane type: Single-girder or double-girder overhead crane, depending on load weight and operating duty.
• Lifting equipment: Spreader beams, lifting beams, or customized shell lifting frames.
• Quantity: Typically 1–2 cranes per production bay, depending on the number of rolling machines and simultaneous lifting operations.

Main operations: Lifting, aligning, positioning, and welding cylindrical shell sections to form the main silo body.

Typical loads handled:

• Small and medium shell sections: approximately 2–10 ton.
• Large cylindrical shell sections: approximately 5–25 ton or more.
• Reinforced shell assemblies: approximately 10–35 ton or more.

Actual weights depend on shell diameter, height, plate thickness, and additional structural components.

Recommended crane configuration:

• Crane capacity: 10–30 ton or higher for heavy assembly applications.
• Crane type: Double-girder overhead crane.
• Lifting equipment: Engineered spreader beams, multi-point lifting beams, or customized shell lifting frames.
• Quantity: Typically 1–2 cranes per assembly bay; larger workshops may require additional cranes for separate production lines.

Key features: VFD-controlled hoisting and travel, suitable lifting height, accurate positioning, and engineered lifting arrangements to maintain load balance and prevent shell deformation.

Main operations: Fabricating hopper sections, discharge cones, roof panels, trusses, and supporting structures before transferring them to final assembly.

Typical loads handled:

• Hopper and cone sections: approximately 2–10 ton.
• Roof panels: approximately 0.5–3 ton.
• Roof trusses and structural frames: approximately 1–8 ton.

Recommended crane configuration:

• Crane capacity: 5–15 ton.
• Crane type: Single-girder or double-girder overhead crane, depending on component weight and workshop requirements.
• Lifting equipment: Standard hooks, lifting beams, spreader beams, or customized lifting frames.
• Quantity: Typically 1 crane per fabrication bay; larger workshops may require separate cranes for hopper and roof production.

Main operations: Handling completed silo sections, positioning assembled structures, transferring finished components to inspection and storage areas, and preparing products for loading and transportation.

Typical loads handled:

• Completed cylindrical sections: approximately 5–25 ton.
• Large silo assemblies: approximately 10–35 ton or more.
• Finished hopper and structural assemblies: approximately 2–20 ton.

Recommended crane configuration:

• Crane capacity: 10–50 ton or higher, depending on the maximum finished component weight.
• Crane type: Double-girder overhead crane for heavy components; single-girder cranes may serve lighter handling operations.
• Lifting equipment: Standard hooks, spreader beams, or customized lifting frames.
• Quantity: Typically 1–2 cranes per assembly or dispatch bay, depending on production volume and handling requirements.

Key features: Adequate lifting height, sufficient runway coverage, VFD-controlled travel, and anti-collision protection where multiple cranes operate on the same runway.

The following table summarizes the crane requirements for different production areas.

Note: Capacities and crane configurations are preliminary references. Final selection depends on the maximum suspended load, lifting attachments, span, lifting height, working duty, workshop layout, and building structure.

The number of overhead cranes depends on the factory's production layout, material handling frequency, and the number of lifting operations that must take place simultaneously.

For example:

• Small and medium-sized factories: Raw material storage and plate preparation may share one crane runway. Plate rolling and general fabrication may also be combined into one workshop.
• Factories with dedicated production lines: Separate cranes may be installed for plate cutting, shell fabrication, and final assembly to reduce material handling delays.
• Large silo manufacturing facilities: Heavy shell assembly and finished product handling may require dedicated high-capacity double-girder cranes.

One crane may serve several workstations if its runway provides sufficient coverage and the lifting operations do not conflict. Where multiple cranes share a runway, wheel loads, operating zones, anti-collision protection, and control arrangements must be considered.

The total crane quantity should therefore be determined from the factory layout and production requirements rather than a fixed number of cranes per workshop.

Raw Material Storage → Steel Plate Cutting → Plate Rolling → Cylindrical Shell Fabrication → Welding and Assembly → Hopper and Roof Fabrication → Final Assembly → Inspection and Dispatch

When planning an overhead crane system, consider the complete production flow, including where materials enter, how components move between workstations, and where finished structures are stored or loaded. This helps determine the appropriate crane capacity, quantity, runway coverage, and lifting attachments for each production area.

Suitable for:

• Small and medium-sized steel plates
• Plate cutting and preparation operations
• Light structural components
• General workshop material handling

Typical application case:

A plate preparation workshop handles steel plates measuring 6 m × 2 m × 10 mm. Each plate weighs approximately 942 kg. A 3–5 ton overhead crane can provide sufficient capacity for handling these plates, provided the lifting attachment and operating conditions are properly considered.

Recommendation:

A single-girder overhead crane is often suitable for this type of application. Plate clamps, vacuum lifters, or lifting beams can be selected according to the plate dimensions, surface condition, and handling method. For frequent plate handling, consider VFD-controlled travel to improve positioning accuracy.

Suitable for:

• Medium-sized steel coils
• Rolled steel plates
• Small cylindrical shell sections
• General fabrication and welding operations

Typical application case:

A silo factory rolls 6–8 mm thick steel plates into cylindrical shell sections for medium-sized silos. Individual sections weigh approximately 3–6 ton and need to be transferred between rolling machines and welding stations.

Recommendation:

A single-girder or double-girder overhead crane may be selected depending on the span, lifting height, working duty, and workshop structure. A spreader beam or customized shell lifting frame can help distribute the load and reduce the risk of deformation during handling.

Suitable for:

• Medium and large cylindrical shell sections
• Hopper and cone assemblies
• Heavy steel fabrication
• Shell positioning and assembly

Typical application case:

A shell fabrication workshop handles cylindrical sections with a diameter of 6–10 m. Depending on the plate thickness, section height, and reinforcements, individual sections may weigh approximately 8–15 ton.

Recommendation:

A double-girder overhead crane is worth considering for heavier components, larger spans, or demanding production duties. The lifting system should be designed around the shell geometry, center of gravity, and lifting points. VFD-controlled hoisting and travel can support smoother lifting and more accurate positioning during assembly.

Suitable for:

• Large silo shell sections
• Heavy fabricated structures
• Large hopper assemblies
• More demanding material handling operations

Typical application case:

A large silo manufacturing workshop assembles reinforced cylindrical shell sections weighing approximately 18–25 ton. The sections must be lifted, rotated or repositioned where required, and aligned for welding.

Recommendation:

A double-girder overhead crane is generally a suitable starting configuration for this load range. For long or large-diameter shell sections, use an engineered multi-point lifting beam or customized lifting frame. Check the lifting points, load distribution, headroom, and available installation space before finalizing the crane design.

Suitable for:

• Heavy silo structures
• Large industrial storage tank components
• Heavy-duty fabrication and assembly
• Oversized components requiring engineered lifting arrangements

Typical application case:

A heavy fabrication workshop manufactures large industrial storage tanks or silo sections. A completed assembly may weigh 35–45 ton and require lifting between fabrication, inspection, and dispatch areas.

Recommendation:

A heavy-duty double-girder overhead crane is commonly considered for this application. Depending on the component dimensions and lifting requirements, the system may use a customized spreader beam, multi-point lifting arrangement, or two-crane synchronized lifting system. Tandem lifting requires coordinated controls and an engineered lifting plan; the combined crane capacities alone do not establish that a lift is safe.

Crane capacity should not be selected based on the weight of the steel component alone. Buyers should also consider:

• Maximum lifted load: Include the workpiece, lifting beam, clamps, spreader, and other suspended accessories.
• Component dimensions: Large-diameter shells and long plates may require special lifting arrangements even when their weight is relatively low.
• Lifting method: Single-point, two-point, and multi-point lifting arrangements affect load distribution and crane selection.
• Lifting height and headroom: Check the required hook travel and available space below the roof structure.
• Working duty: Evaluate lifting frequency, operating hours, load spectrum, and required ISO or FEM duty classification.
• Workshop structure: Verify runway beam capacity, building columns, wheel loads, and available installation space.

Yuantai Crane Recommendation: For silo manufacturing projects, we recommend selecting the crane based on the heaviest component handled in each production area, together with its dimensions and lifting method. Providing component drawings, maximum load weights, workshop span, lifting height, and operating frequency will help our engineering team recommend a suitable crane capacity and configuration.

A cylindrical silo shell can also be estimated using its diameter, height, and plate thickness.

Formula:

Shell weight (kg) ≈ π × Diameter (m) × Height (m) × Thickness (mm) × 7.85

Examples:

Example for crane selection:

A cylindrical shell section with a diameter of 10 m, a height of 3 m, and a thickness of 10 mm weighs approximately 7.4 ton.

If its lifting frame and slings weigh another 1.5 ton, the total suspended load is approximately 8.9 ton.

A 10 ton overhead crane could be considered for preliminary evaluation, subject to checking the complete lifting arrangement and applicable design requirements.

For large cylindrical shells, a spreader beam or customized lifting frame can help distribute the load and prevent shell deformation during lifting.

Note: These formulas estimate the main steel plate only. They do not include stiffeners, flanges, support rings, reinforcement plates, or other attached components. Use fabrication drawings to confirm the actual weight.

When selecting an overhead crane, do not calculate only the weight of the steel component. Include all equipment suspended from the crane hook.

The total suspended load is the combined weight of the workpiece and its lifting equipment.

A silo factory needs to lift a cylindrical shell section using a customized spreader beam.

The total suspended load is 10 ton.

A 10 ton overhead crane would have no remaining rated-capacity allowance for additional unaccounted loads. The engineering team should therefore evaluate a higher crane capacity, such as 12.5 ton or 16 ton, as possible options.

The final selection must be checked against the lifting arrangement, crane design requirements, and operating conditions.

Other silo components can be estimated using their material dimensions and fabrication drawings.

For irregular or reinforced components, use the fabrication drawings or material list to calculate the weight more accurately.

After estimating the component weight, follow these steps:

1. Find the heaviest load: Identify the heaviest component the crane needs to handle.
2. Add lifting equipment: Include the weight of spreader beams, lifting frames, slings, and clamps.
3. Check the lifting method: Consider the component dimensions, lifting points, and load balance.
4. Choose a preliminary crane capacity: Make sure the rated capacity covers the complete suspended load.
5. Confirm workshop conditions: Check the crane span, lifting height, working frequency, duty class, and building structure.

Send us your maximum lifting weight, component dimensions, workshop span, lifting height, and fabrication drawings. Yuantai Crane's engineering team can help recommend a suitable crane capacity, crane type, and lifting arrangement for your production requirements.

A double-girder overhead crane uses two main bridge girders supporting a trolley or hoisting mechanism.

It is commonly considered for:

• Heavy cylindrical shell handling.
• Large silo assembly.
• Heavy structural fabrication.
• Higher lifting height requirements.
• More demanding operating duties.

Main characteristics:

• Suitable for higher lifting capacities.
• Can accommodate open-winch hoisting systems.
• Provides flexibility for heavy-duty trolley configurations.
• Can be engineered for demanding industrial applications.

Typical preliminary capacity range: 10–50 ton or higher.

A low-headroom overhead crane is designed to reduce the space required between the hook and the crane runway structure.

It can be considered when:

• Workshop roof height is limited.
• The factory requires greater usable hook height.
• Existing building dimensions restrict conventional crane arrangements.

single girder low headroom overhead crane

double girder low headroom overhead crane

The final design depends on the available headroom, hook approach, lifting height, and runway arrangement.

The choice should be based on rated capacity, span, lifting height, duty, wheel loads, building structure, and total project cost rather than crane type alone.

C-hooks and coil lifting devices are used to handle steel coils.

Important selection parameters:

• Coil weight.
• Coil inside diameter.
• Coil outside diameter.
• Coil width.
• Horizontal or vertical coil orientation.

Spreader beams and lifting beams are useful for handling long plates, cylindrical sections, and large fabricated components.

They help distribute lifting forces across multiple lifting points when properly designed.

Selection considerations:

• Beam length.
• Rated capacity.
• Lifting point spacing.
• Load center of gravity.
• Deflection and structural strength.

Customized lifting frames may be required for:

• Large cylindrical shell sections.
• Hopper and cone structures.
• Irregularly shaped components.
• Large fabricated assemblies.

The lifting frame should be designed according to the component geometry, lifting points, and required handling orientation.

Before selecting the crane, buyers and engineers should verify:

1. Maximum component weight.
2. Attachment self-weight.
3. Rigging and sling weight.
4. Load center of gravity.
5. Number and position of lifting points.
6. Component strength and deformation limits.
7. Applicable lifting design and safety requirements.

A lifting attachment must be included in the suspended-load calculation, not treated as an independent accessory outside the crane capacity.

Typical applications:

• Medium and large cylindrical shell handling.
• Shell section alignment.
• Welding and assembly operations.
• Hopper and structural component handling.

Illustrative configuration:

• Capacity: 15–20 ton.
• Span: 20–25 m.
• Lifting height: 8–12 m.
• Crane type: Double girder.
• Lifting equipment: Customized spreader beam.
• Control: Radio remote control or cabin, depending on the operation.
• Optional feature: Variable frequency drives for controlled movement.

Typical applications:

• Large cylindrical shell assemblies.
• Heavy hopper structures.
• Large fabricated components.
• Heavy-duty production and assembly areas.

Illustrative configuration:

• Capacity: 30–50 ton.
• Span: 22–31.5 m.
• Lifting height: 10–15 m.
• Crane type: Double girder.
• Lifting equipment: Engineered lifting frame or spreader beam.
• Control: Cabin or radio remote control.
• Optional feature: VFD-controlled hoisting and travel.

All example configurations are preliminary references. Final specifications depend on the actual component drawings, building dimensions, runway conditions, lifting accessories, and operating duty.

A large cylindrical shell may require a customized lifting arrangement even when its weight is within the crane's rated capacity.

The maximum component height, lifting device dimensions, and required clearance must be considered together.

Steel plates, coils, cones, and cylindrical sections may require different attachments.

A crane used continuously in a production line may require a different duty classification from one used occasionally for material transfer.

Runway beams, columns, and connections must be checked against the proposed crane wheel loads and horizontal forces.

A crane selected only for current loads may not support larger components or increased production capacity in the future.

To recommend a suitable overhead crane, the manufacturer needs information about the lifting loads, workshop dimensions, operating conditions, and electrical supply. The following checklist can help buyers prepare their inquiry.

Not every buyer has finalized crane specifications at the inquiry stage. You can still request a preliminary proposal by providing:

• Photographs of the materials and components to be lifted.
• Available component drawings.
• Estimated maximum load weight.
• Approximate component dimensions.
• Workshop layout or building drawings.
• Description of the manufacturing process.

The engineering team can review the available information and help identify the appropriate crane type, preliminary capacity, lifting arrangement, and additional technical requirements.

A double-girder overhead crane is commonly considered for medium and heavy cylindrical shell sections. It can be equipped with a customized spreader beam or lifting frame. The final configuration depends on shell diameter, weight, lifting points, span, and required lifting height.

Single-girder cranes are often suitable for general plate handling and light-to-medium fabrication. Double-girder cranes are commonly preferred for heavier shell assembly, large fabricated structures, and demanding lifting operations. The decision should also consider span, duty, headroom, and building structure.

For a thin cylindrical steel shell, an approximate calculation is:

Shell weight (kg) ≈ π × Diameter (m) × Height (m) × Thickness (mm) × 7.85.

This provides the basic shell weight. Stiffeners, flanges, reinforcement rings, openings, and other attached components must be added separately.

Common attachments include plate clamps, vacuum lifting devices, steel coil C-hooks, spreader beams, lifting beams, and customized lifting frames. The correct device depends on the load shape, dimensions, weight, center of gravity, and lifting orientation.

The required lifting height depends on the maximum component height, the lifting attachment, the workshop layout, and the clearance needed for transportation and assembly. Buyers should provide the maximum height of the components and the required clearance above the floor.

A single overhead crane may handle multiple load types if its rated capacity, lifting attachments, hook arrangement, operating coverage, and lifting procedures are suitable for all intended operations. Specialized attachments or separate cranes may be necessary for different production areas.

The appropriate duty classification depends on lifting frequency, load spectrum, operating hours, and working cycles. ISO 4301 and applicable FEM classifications can be used to determine the required duty. The engineering team should evaluate actual operating conditions before assigning a classification.

The crane span is determined by the distance between the runway rail centerlines and the required working coverage across the workshop. Runway length depends on the longitudinal production area that needs to be served. Building drawings and the factory layout are useful for determining both dimensions.

The most important information includes maximum load weight, component dimensions, lifting height, crane span, runway length, operating duty, power supply, and building dimensions. Component drawings, photographs, and factory layout drawings can help the manufacturer prepare a more accurate technical proposal.