Selecting the right overhead crane is about fit, not just capacity. The best choice balances hook height, headroom, duty class, span, mobility, and lifecycle cost. This guide compares the most common configurations, explains key components and operating principles, and outlines when specific setups – like portal cranes – make sense.
Overhead Crane Components and Parts
Every system is built from the same core building blocks: runway beams and rail, end trucks, single or double girders, a trolley, a hoist, hook and below-the-hook gear, electrification and controls, end stops and buffers, and safety devices. Understanding the components of overhead crane systems helps you compare options confidently and plan maintenance around wear items like wheels, rope or chain, brakes, and couplings. Use overhead crane parts consistently in your documentation so spares and inspections line up across sites.
Overhead Crane Operations
Operations come down to three motions: lift and lower, cross travel, and long travel. Performance depends on duty class, speed control, and how well the crane manages load sway. Modern controls improve positioning and repeatability, while good operator visibility, lighting, and clear pedestrian routes make daily work safer and faster. Build standard operating procedures for start-up checks, safe rigging, controlled movements, and hand-over at shift changes.
Single Girder vs Double Girder Bridge Cranes
Single girder suits moderate capacities with a lighter structure and a strong cost-to-performance ratio. Double girder carries heavier loads, longer spans, and gains extra hook height because the hoist can travel between or on top of the girders. If you need future expansion, double girders often create more headroom for process equipment or tall loads.
Top-Running vs Under-Running
Top-running cranes travel on top of runway beams and handle larger capacities and spans. Under-running (under-hung) cranes suspend from the runway and excel where floor space and hook approach are critical on lighter service. Building steel, headroom, and the process path usually decide this choice.
Hoist Selection: Chain vs Wire Rope
Chain hoists are compact, easy to clean, and ideal for frequent, precise lifts at lower capacities. Wire rope hoists cover higher capacities and faster lifting with better heat dissipation on heavy cycles. Match the hoist to duty class, environment, and the precision your operators need.
Decision Factors Before You Buy
Confirm span and capacity, hook height and headroom, building steel and runway readiness, electrification and control approach, environmental conditions, duty class and cycle counts, and the path loads will follow. Include a plan for inspections, spare parts, and routine maintenance so performance remains consistent throughout the crane’s service life.
How RGM Cranes Can Help
RGM Cranes designs and commissions overhead crane systems that match process requirements, building constraints, and duty demands. The team assists with configuration selection, hoist and control specification, and ensures each installation includes a clear inspection and maintenance plan. Whether you’re upgrading, expanding, or comparing options, RGM helps translate production needs into reliable, compliant lifting solutions.
Frequently asked questions
What are the main overhead crane components?
Runway beams and rails, end trucks, single or double girders, trolley, hoist, hook and below-the-hook gear, electrification and controls, end stops or buffers, and safety devices.
When should I choose an overhead crane gantry instead of a bridge crane?
Use a gantry when building steel is limited, you need indoor-to-outdoor coverage, or you want a mobile solution without permanent runways.
