Project Background
Client:Integrated steel recycling plant in Karachi, Pakistan
Core Challenge:
①Manual unloading of scrap-filled 40ft containers caused severe bottlenecks (avg. 10 containers/day), risking worker injuries during tilt-dumping operations.
②Existing equipment failed in extreme conditions: airborne metal dust, 45℃ temperatures, and voltage instability (300–420V fluctuations).
Solution Objective:
Deploy a 32T Rail-Mounted Gantry Crane (RMG) with dual-winchtrolleys and cable-reel power to automate scrap handling.
Key specifications:
Capacity：32 tons(Handles loaded 40ft scrap containers）
Span：30m(Covers dual rail tracks + service lane ）
Lifting Height：16m(Over the 12m high pile of scrap steel that was stacked up）
Duty Class：A6(Heavy cyclic，Supports 18-hr/day operation）
Power Supply：380V/50Hz/3Ph（Matches Pakistan grid)
Propulsion：Rail-mounted w/cable reel(150m armored cable for yard mobility)
Using two small vehicles running simultaneously, one on the left and the other on the right, with the hook moving up and down, this achieves the effect of loading, unloading and tipping. The material grasping function can also be combined with the orange peel grabber to replace the hook.
Sinoko Container Gantry Crane Key Features
①Twin Winch Trolley System:
Synchronized electric hoists enable balanced force distribution during tilt-dumping, preventing container slippage under uneven scrap loads.
②Dust-Immune Components:
IP56-rated electrical cabinets with forced-air cooling (ambient 45°C tolerance).
Hardox 500 wear plates on spreader corners resist abrasive scrap abrasion.
③Anti-Sway & Tilt Control:
12-rope damping system minimizes container swing during lifting, while hydraulic cylinders enable controlled 65° tilting for complete scrap ejection.
④Cable Reel Power System:
Auto-tensioning drum-fed cable ensures uninterrupted 380V power across 200m yard traverse, with surge protection for voltage spikes.
⑤Smart Collision Avoidance:
Laser scanners detect obstacles in crane path, triggering automatic stops to protect rail alignment.
Implementation Process
The Sinoko Container Gantry Crane will conduct on-site inspections of the working conditions and design a complete set of solutions for the client. The progress of the entire project is as follows:
Phase 1: Site Preparation
| Task | Challenge | Solution |
| Railway Installation | A track for the crane must be installed | Driven piles (16m depth) + laser-leveled tracks (±2mm flatness) |
| Power Stabilization | Voltage fluctuations (300–420V) | Installed 10% voltage regulators at substation |
| Dust Mitigation | Airborne metal particles | Enclosed operator cabin with HEPA filtration |
Phase 2: Crane Commissioning & Training
Structural Assembly:
Bolt-free main beam connections reduced vibration-induced loosening risk.
Dual-Trolley Syncing:
Calibrated winches for simultaneous operation (±0.5% speed variance).
Tilt-Dump Simulation:
150 test cycles with mixed scrap (shredded steel/turnings), achieving 98% material ejection rate.
Localized Training:
Training for operators, covering emergency handling procedures and sling maintenance content.
Phase 3: Load & Safety Validation
125% Load Test (40T): Confirmed ≤6mm girder deflection at full span.
Emergency Stop Response: ≤2.0 sec halt at 12m/s wind speed (per FEM standards).
Project Outcomes
After the customer's use, Sinoko Container Gantry Crane operational performance metrics:
| KPI | Pre-Install | Post-Install | Improvement |
| Daily Containers Handled | 10 | 36 | +260% |
| Unloading Time | 50min | 10min | -80% |
| Scrap Residue | 12% | 1.5% | -87.5% |
| Worker Injuries (Monthly) | 3 | 0 | 100% reduction |
Compliance: Exceeded ISO 14001 environmental protocols.
Application Areas
This RMG solution has been optimized for customers in Pakistan. Besides, Sinoko gantry cranes are also applicable to the following industries:
Port Terminals：Container sorting at dry ports
Rail Freight：Transloading metal scrap，Rail-to-truck transfer.
Construction：Handling rebar bundles,Optional magnet attachment integration.
Key Achievement
The sinoko container gantry crane dual-trolley synchronization enabled simultaneous lifting of container corners during tilting—preventing torsion damage when ejecting compacted scrap. This resulted in a 14-month ROI, prompting a repeat order for two additional cranes at the client’s Lahore facility.
There are various forms of gantry cranes for you to choose from. You can select the appropriate gantry crane based on different environments, working conditions, and the tonnage of the materials.
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