Customizing the Span, Height, and Capacity of Your Heavy Duty Gantry Crane

When it comes to lifting and transporting heavy loads in industrial environments, heavy duty gantry cranes offer a robust, flexible, and reliable solution. These cranes are commonly used in shipyards, steel mills, construction sites, precast concrete plants, power plants, and large warehouses. However, to ensure optimal performance and cost-efficiency, it is essential to customize key parameters of the gantry crane—namely the span, lifting height, and load capacity—based on the specific operational needs of your facility.

This article explores why these customizations are crucial and how businesses can make the best decisions when investing in a heavy duty gantry crane system.

Why Customization Matters

No two job sites are exactly the same. From the size of the workspace and the type of loads handled, to how frequently the crane is used and the materials lifted—every detail impacts what kind of gantry crane you need. Off-the-shelf cranes may fall short in performance, safety, or space efficiency. That’s why customization is not a luxury, but a necessity for high-capacity lifting equipment.

Tailoring the span, height, and capacity helps achieve:

• Improved workflow efficiency

• Better space utilization

• Increased safety

• Lower long-term costs

• Future-proofing for evolving operational needs

Customizing the Span: Bridging the Operational Gap

What Is Span?

The span of a gantry crane refers to the distance between the two support legs. It determines the horizontal working area of the crane. For overhead gantry cranes, the span needs to align with the layout of the workplace, including aisle widths, rail positions, and load zones.

Key Considerations

1. Facility Layout: Measure the width of the working area and consider potential obstructions like buildings, containers, or fixed equipment.

2. Load Transfer Path: The span should support the full travel of loads between pickup and drop-off points.

3. Rail vs Rubber Tyred Setup: For rail mounted gantry cranes (RMG), the span defines the rail gauge and should be precisely aligned with existing tracks. For rubber tyred gantry cranes (RTG), wider spans increase flexibility but may reduce turning radius.

Typical Span Ranges

• Medium to large gantry cranes: 10 to 40 meters

• Extra-wide applications (such as shipyards): Up to 60 meters or more

Customization Tips

• Use CAD layouts or site drawings to simulate crane movement.

• Factor in future expansion plans or new bays.

• Avoid over-sizing—the wider the span, the greater the cost and complexity.

Customizing the Lifting Height: Reaching the Right Elevation

What Is Lifting Height?

The lifting height refers to the vertical distance the hook can travel—from the ground (or pit) to the maximum lifting point. It defines the height of items that can be lifted and stacked.

Key Considerations

1. Load Dimensions: Taller loads require higher lifting heights to ensure safe clearance during lifting and travel.

2. Storage Needs: In storage yards or container depots, the height must support stacking multiple items or containers.

3. Working Below Ground: In some applications like tunnel lifting or furnace operations, cranes may need a hook that descends below floor level.

Custom Heights

• Standard lifting heights: 6 to 18 meters

• Specialized heavy duty cranes: 20+ meters

• Pit or underground applications: May require 5–10 meters below-ground lift

Customization Tips

• Measure the tallest object and add safe clearance (at least 1–2 meters).

• Consider the crane’s self-weight and reeving height.

• Avoid excessive height if not needed—it can add unnecessary cost and complexity.

Customizing the Load Capacity: Matching the Weight Challenge

What Is Load Capacity?

Load capacity is the maximum weight the crane can safely lift. For heavy duty gantry cranes, this can range from 20 tons to hundreds of tons, depending on the structure, hoist mechanism, and power system.

Key Considerations

1. Type of Loads: Know your heaviest expected load and its frequency. Overestimating too much increases cost; underestimating risks safety.

2. Single vs Dual Lifting: In some projects (e.g., concrete beam lifting), you may need twin hoists or dual trolley systems for long or unbalanced loads.

3. Future Requirements: Build in extra margin if your operations are expected to scale.

Capacity Range Examples

• Construction/industrial: 20–100 tons

• Shipyard and heavy fabrication: 100–500 tons

• Special projects (hydropower, metallurgy): 500+ tons

Customization Tips

• Consult with engineers for dynamic load analysis, especially for handling items with shifting center of gravity.

• Choose A5 or A6 duty rating for medium-heavy use; A7-A8 for high-frequency or extreme lifting conditions.

• Consider modular hoisting systems for multi-point or synchronized lifting.

Integrating All Three Factors for Optimal Design

The ideal gantry crane is a balanced system, where span, height, and capacity work in harmony to support your workflow.

Example: A Precast Concrete Yard

• Span: 25 meters to cover wide concrete mold layout

• Lifting height: 10 meters to handle tall precast elements

• Capacity: Dual 25-ton hoists for synchronized 50-ton lifting

Example: A Shipbuilding Facility

• Span: 40 meters to straddle ship sections

• Height: 15–20 meters for hull components

• Capacity: 200 tons or more, often with tandem hoists

Additional Customization Options

In addition to span, height, and capacity, consider these options:

• Cantilever Design: For overhanging pick-up zones

• Anti-sway technology: For precision handling of large or fragile loads

• Power supply mode: Diesel, cable reel, or hybrid

• Control mode: Cabin, wireless remote, or ground pendant

• Mobility systems: Fixed rail, rubber tyres with 360° steering, or trackless systems

Partner with the Right Gantry Crane Supplier

Customization requires more than selecting specs from a dropdown—it involves engineering, consultation, and a thorough understanding of your site and lifting needs. That’s why it’s critical to partner with a reliable gantry crane manufacturer with proven experience in custom heavy duty solutions.

At Aicrane, we specialize in designing, fabricating, and installing tailor-made gantry cranes with capacities from 20 to 500+ tons, engineered to meet exact customer specifications. Our technical team works closely with clients to evaluate site layouts, lifting requirements, and operational goals, ensuring the final solution is safe, efficient, and cost-effective.

Conclusion

Customizing the span, lifting height, and load capacity of your heavy duty gantry crane isn’t just about technical specs—it’s about optimizing your entire operation. By carefully assessing your needs and working with a knowledgeable supplier, you can ensure your gantry crane investment pays off for years to come.

Ready to build the ideal crane for your operation?Contact Aicrane today for a free consultation and layout evaluation. We’ll help you lift smarter, safer, and more efficiently.