32 Ton Overhead Crane System for Aluminum Processing Plant in Saudi Arabia

High-Temperature Operation

Some cranes work near reheating furnaces.

The environment includes:

• Continuous heat exposure.
• Thermal radiation.
• Heavy-duty lifting cycles.

The customer required the crane to maintain stable performance under temperatures up to 400°C.The challenge was not only lifting the load.The electrical system, cables, and operator cabin also needed protection.

Stable Lifting for Aluminum Materials

Aluminum coils and slabs require accurate handling.

During operation, sudden acceleration or braking may cause load swing.

Excessive swing can:

• Affect positioning accuracy.
• Increase operation risk.
• Slow down production.

Therefore, the customer required all cranes to include an anti-sway system.

Safe Operation of Multiple Cranes

Several cranes operate on the same runway.

Without proper coordination, crane interference may happen.

The customer required a reliable anti-collision system to improve safety during daily production.

Complete Main Girder Transportation

The main girder length reached 29 meters.

The customer required:

• No cutting.
• No field welding.
• Complete structural delivery.

The transportation method needed to protect the original crane structure.

Customized Engineering Solutions

High-Temperature Resistant Crane Design

For furnace charging applications, Yuantai Crane applied special high-temperature protection.

The solution included:

High-Temperature Resistant Cables

Special cables were selected to withstand continuous heat exposure.

They help prevent:

• Cable aging.
• Insulation damage.
• Signal failure.

This ensures stable power supply and reliable control.

Heat-Insulated Operator Cabin

The operator cabin was equipped with rock wool insulation.

The insulation layer helps reduce heat transfer from the working environment.

It improves operator comfort and protects control components inside the cabin.

Semi-Automatic Control System

The furnace charging cranes were equipped with a semi-automatic control system.

The system includes:

• 37 preset positioning points.

Operators can select the required position for repeated charging operations.

The system improves:

• Positioning accuracy.
• Operation efficiency.
• Production consistency.

At the same time, manual control remains available.

Because in real production, operators still need flexibility.

Anti-Sway System for Precise Lifting

To improve lifting stability, all cranes were equipped with an anti-sway system.

The system integrates:

• PLC control.
• Variable frequency drive.
• Encoder feedback.

It monitors load movement during:

• Starting.
• Acceleration.
• Traveling.
• Braking.

The crane automatically adjusts movement speed to reduce swing.The system reduces load swing by more than 95%.For aluminum handling, this means safer lifting and more accurate positioning.

Safety Protection Systems

Safety was a key requirement for this project.

The cranes were equipped with multiple protection devices.

Infrared Anti-Collision System

For cranes operating on the same runway:

• The system monitors crane distance.
• It provides warning signals.
• It slows down or stops movement when required.

This helps prevent crane collisions.

Additional Safety Devices

The cranes also include:

• Overload protection system.
• Lifting height limiter.
• Travel limit switches.
• Hook safety latches.

These systems provide additional protection during daily operation.

Main Girder Transportation Solution

The 29 m main girder could not fit into standard containers.

Instead of cutting the girder, Yuantai Crane selected bulk vessel transportation.

The transportation plan included:

• Complete main girder shipment.
• Waterproof protection.
• Separate packing for hoists and electrical components.

Hoists and electrical parts were packed in wooden cases and shipped by container.

This approach maintained structural accuracy and reduced installation work at the customer's site.

Manufacturing, Inspection and Delivery

Before shipment, the cranes completed factory inspection.

The project passed SGS inspection and met the customer's quality requirements.

Inspection included:

• Crane structure checking.
• Mechanical system inspection.
• Electrical system testing.
• Safety device testing.
• Operation performance testing.

After delivery, the cranes were successfully installed and put into operation.

Project Results

The 9 overhead cranes now support daily production in the Saudi aluminum plant.

The system provides:

• Stable Material Handling: The cranes handle aluminum coils, rolls, and production equipment safely.
• Reliable High-Temperature Operation: The furnace charging cranes operate successfully in environments up to 400°C.
• Improved Lifting Accuracy: The anti-sway system helps operators achieve smoother movement and accurate positioning.
• Safer Multi-Crane Operation: The anti-collision system improves coordination between cranes working on the same runway.

Why Yuantai Crane Was Selected

For aluminum and metallurgy industries, crane selection is not only about lifting capacity.

The key is whether the crane can match the production environment.

This project required:

• High-temperature protection.
• Precision lifting control.
• Multiple safety systems.
• Special transportation planning.

Yuantai Crane provided a complete engineering solution from design to delivery.

We focus on solving practical problems faced by industrial customers.

A reliable crane is not only equipment.

It supports continuous production and long-term operation.