Case: 40 Ton Explosion-Proof Overhead Crane for Sale – Germany

Explore how a 40 ton explosion-proof crane meets German safety standard with reliable design & precision weld inspection. Get custom 40 ton overhead crane!

Overview of 40 Ton Explosion Proof Overhead Cranes

This project is about delivering a 40-ton explosion-proof overhead crane to a customer in Germany. The customer runs a facility where flammable or explosive materials are handled. Safety and reliability were their top priorities.

They needed a workshop crane that could handle heavy lifting, but also meet strict explosion-proof standards in Europe. The installation site had specific size and power requirements. After discussions, we proposed a customized QB-type explosion proof overhead crane.

QB explosion proof overhead crane for sale 

Customer Requirement at a Glance

The client was clear about a few key points:

• The crane must be explosion-proof, suitable for hazardous areas.
• It must have a lifting capacity of 40 tons.
• The crane span needed to be 22 meters to match their workshop layout.
• The lifting height had to be 18 meters to meet production needs.
• Their power supply is 400V, 50Hz, 3-phase – common in European plants.

They also requested:

• A CE-certified product.
• Low maintenance design, with easy access for servicing.
• Reliable hoisting and stable long-term use, even in a tough environment.

Why Explosion-Proof Was Critical

The working area handles gases and dust that could ignite. So, every part of the crane – motor, control box, wiring, and even the wheels – had to be sealed, spark-proof, and ATEX-compliant. This wasn't just about passing a test; it was about real protection, every day.

Our Approach

We didn’t offer a one-size-fits-all solution. Instead:

• We customized the crane based on their site drawings and requirements.
• Explosion-proof motors and control systems were used.
• Protective measures were added to both electrical and mechanical parts.
• We made sure all components followed EU safety standards.

This project reflects our focus on safe, strong, and smart lifting solutions for sensitive industries. More than just selling a crane, we helped solve a problem.

Client Background

The client is a German industrial company involved in chemical production and hazardous materials processing. Their facility handles various flammable gases and volatile chemicals during daily operations. Because of this, safety regulations at their plant are very strict.

They operate in an ATEX Zone 1 environment, where there's a constant risk of explosive gas or vapor. In areas like this, any spark or electrical fault could cause serious accidents. That’s why they only use certified explosion-proof equipment.

A Quick Look at Their Working Conditions

• High-temperature processes
• Flammable gas pipelines running across the plant
• Heavy-duty material handling (raw materials and containers up to 40 tons)
• Long operational hours (two shifts, sometimes 24/7)
• High expectations for machine durability and safety compliance

Their workshop had overhead runways ready, but needed a new crane to match their production capacity. The old crane they had was too small, and more importantly, not explosion-proof. They couldn’t take the risk anymore.

What the Client Needed from Us

They didn’t just want a crane – they needed a safe and smart lifting solution that could:

• Lift 40 tons safely without failures.
• Work quietly and smoothly over a 22-meter span.
• Lift up to 18 meters high, to handle large chemical tanks.
• Be fully explosion-proof, certified, and low-risk in every component.
• Integrate with their existing control system and match their 400V, 50Hz, 3-phase power supply.

Above all, their main goals were:

• Safety – no compromises. Every component had to meet ATEX and CE standards.
• Efficiency – the crane had to speed up production, not slow it down.
• Reliability – long-term, stable performance with minimal downtime.

They were not first-time buyers. They had experience with overhead cranes and knew exactly what to ask – and we were ready with the answers.

Project Requirements

The client’s project involved more than just installing a heavy-duty crane. It required a highly specialized lifting solution designed for safe operation in a hazardous environment. All specifications had to align with the client’s safety goals, facility conditions, and long-term operational needs.

Basic Crane Specifications

The core mechanical and electrical requirements of the crane were clearly defined by the client. These specs formed the starting point for our design and engineering work.

Explosion-Proof and Safety Requirements

Because the facility handles flammable gases and vapors, explosion protection was non-negotiable. The client requested full compliance with European safety standards to ensure safe and uninterrupted operations.

• ATEX compliance for use in explosive gas zones
• CE marking and adherence to EN safety standards
• Explosion-proof design for hoisting motors, travel drives, and control systems
• Enclosed, flameproof control cabinets and electrical wiring
• Non-sparking materials used in key contact components, such as hooks and wheels

Structural and Mechanical Design Needs

The crane had to withstand frequent use in a demanding environment, with minimal downtime. The client emphasized mechanical strength and easy maintenance.

• Durable, welded steel structure for stability and load endurance
• Low-maintenance layout with easy access to all major parts
• Smooth and quiet movement for safer load handling
• Long service life, even in dusty or high-temperature conditions

Integration with Existing Workshop

Since the workshop was already equipped with support beams and a power system, the crane had to be customized to fit seamlessly into the current setup.

• Exact span and rail gauge alignment with existing runway beams
• Hook travel adjusted to match working areas and process flow
• Electrical connections tailored to the facility’s 400V power system
• Consideration of ceiling clearance, column spacing, and access for maintenance

Planning Inputs from Client

To ensure that the crane met every technical and operational detail, the client shared precise design references. This helped us reduce installation time and avoid costly on-site changes.

• Full workshop layout with structural dimensions
• Environmental details, including dust levels and temperature range
• Required lifting points, working zones, and motion limits

Open winch of 40 ton explosion proof overhead crane for sale Germany
End carriages of 40 ton explosion proof overhead crane for sale Germany

Main Girders of 40 ton explosion proof overhead crane for sale Germany

Engineering & Design Solutions

To meet the client's strict safety and operational requirements, we provided a fully customized explosion-proof overhead crane. Every component was carefully selected and adapted to handle daily work in a hazardous, high-risk industrial environment.

Customization for Hazardous Environment

The crane was designed with full awareness of the flammable materials present in the workshop. All exposed components were reviewed for spark risks, and safety zones were taken into account during layout planning.

• All mechanical and electrical parts met ATEX standards
• System layout and wiring were enclosed to prevent exposure to gas or dust
• Structural design matched the facility’s explosion hazard classification

Explosion-Proof Components

Explosion protection was applied throughout the crane system, not just the motors. All electrical parts and operating systems were certified to operate safely under potential gas exposure.

• Explosion-proof hoisting and travel motors with flameproof enclosures
• Flameproof electrical control cabinets, sealed from outside contact
• Limit switches and wiring systems enclosed to prevent arcing
• Explosion-proof pendant control, safe for daily handling by operators

Sealed and Spark-Resistant Elements

To further reduce ignition risk, several additional protective features were integrated into the crane design.

• Fully sealed control system, minimizing electrical exposure
• Use of spark-resistant wheels and hooks, if required by the zone rating
• Insulated cable tracks and covered junction points

Material Selection and Surface Protection

Since the crane will operate long-term in a chemically active environment, corrosion resistance was also considered a key design goal.

• Main steel structures treated with anti-corrosion paint systems
• Key components made from corrosion-resistant alloys where necessary
• Surface coatings applied to resist chemical vapors and airborne moisture

Safety Systems and Overload Protection

To ensure stable and secure operations, the crane was equipped with several safety layers, allowing operators to handle heavy loads with confidence.

• Overload limiters to prevent excessive lifting forces
• Travel and lifting limit switches to control movement ranges
• Emergency stop functions built into the pendant control
• Motor thermal protection to reduce wear and fire risk during overuse

Explosion proof parts and components  of 40 ton explosion proof overhead crane for sale Germany
 

Manufacturing & Quality Assurance

Once the design was finalized, we moved into production with a clear focus on precision, safety, and quality. The entire process was planned to meet both international standards and the client’s expectations for durability and reliability in an explosive environment.

Manufacturing Process Overview

Each part of the crane was manufactured in-house at our facility in Xinxiang, China. We followed a strict production schedule to ensure quality at every stage.

• Raw material inspection before fabrication
• CNC cutting, welding, and machining for structural components
• Motor and electrical system assembly by certified technicians
• Quality checkpoints after each major process
• Final assembly and calibration before testing

Compliance with International Standards

The crane needed to meet multiple certification requirements for export and operation in the EU. All components were selected and tested to comply with relevant regulations.

• ISO 9001:2015 quality management system followed throughout production
• CE marking for machinery safety and electrical systems
• ATEX certification for explosion-proof components
• Internal audits and documentation maintained for each compliance step

Third-Party Inspection & Testing

To provide additional assurance, the client arranged third-party inspection through an approved European agency. We welcomed this and coordinated all necessary checks at the factory.

• Dimensional checks and visual inspections of main structure
• Functional testing of hoisting, travel, and control systems
• Verification of explosion-proof ratings and certifications
• Review of material traceability and compliance documents

Factory Testing & FAT Highlights

Before shipment, we conducted a full Factory Acceptance Test (FAT). The client was invited to review the testing process remotely through videos, photos, and reports.

• Full-function trial run of hoisting and travel mechanisms
• Load testing under controlled conditions
• Demonstration of emergency stop, limit switches, and overload protection
• Photos and videos showing labeled components and safety features
• FAT report signed and approved before packing and delivery

Logistics & Delivery

After the crane passed final inspection, we moved forward with export preparations. The logistics plan was carefully managed to ensure safe, on-time delivery from our factory in China to the customer’s site in Germany.

Packing and Transport Arrangements

Proper packing was essential to protect the crane during long-distance transport. We followed export-grade packaging standards for all components.

• Steel structures (main girder, end trucks) wrapped in protective plastic and secured with steel frames
• Electrical panels and motors packed in wooden crates with internal cushioning
• Rust-proof coatings applied to exposed surfaces before shipment
• Clear part labeling for easy unloading and installation

Handling of Oversized Cargo

Some crane parts, especially the main girders and hoisting mechanism, were oversized and required special handling and transport documentation.

• Girders transported as breakbulk cargo to avoid damage
• Custom brackets used to secure large parts on flatbed trailers
• Advance coordination with port authorities for cargo handling
• Route planning in both China and Germany to avoid delays

Delivery Timeline and Coordination

Timely delivery was a key requirement from the client, especially as the crane installation was part of a larger production line upgrade.

• Production and delivery schedule agreed upon during the contract stage
• Delivery completed within the 10–12 week lead time
• Weekly progress updates sent to the client during manufacturing and transit
• All customs documents, certificates, and packing lists prepared in advance for smooth clearance

Results & Customer Feedback

After commissioning, the 40-ton explosion-proof overhead crane was successfully put into daily operation. The performance met the client's expectations and helped improve safety and efficiency in their hazardous work environment.

Performance After Installation

The crane has been operating smoothly since installation. It performs reliably during heavy-duty shifts and handles large materials without issues.

• Stable hoisting and travel, even with full 40-ton loads
• Precise positioning of loads across the 22-meter span
• Smooth acceleration and deceleration with reduced sway
• No overheating or fault alarms during extended use

Client Satisfaction

The client expressed strong satisfaction with the crane’s quality and overall handling. They were especially pleased with the focus on explosion protection and the smooth coordination throughout the project.

• Positive feedback on the explosion-proof features and build quality
• Operators reported ease of use and confidence in crane safety
• Maintenance staff appreciated the clean layout and accessibility of parts
• Communication with our technical team was rated as responsive and helpful

Improvements in Production & Maintenance

Though it’s still early, the client noted clear operational benefits shortly after the crane went into service.

• Faster material transfers reduced handling time per shift
• Improved workplace safety reduced downtime for inspections
• More reliable lifting allowed them to handle sensitive loads with better control
• Fewer manual operations led to lower physical strain on workers

This successful delivery and installation strengthened our relationship with the client and set a solid example of how customized explosion-proof cranes can improve both safety and productivity in high-risk environments.

Why the Client Chose Yuantai Crane

The client had several options when selecting a supplier for their explosion-proof overhead crane. Ultimately, Yuantai Crane stood out because of our specialized expertise, commitment to quality, and strong customer support. Here’s why they chose us:

Specialized Expertise in Explosion-Proof Cranes

Yuantai Crane has years of focused experience designing and manufacturing cranes for hazardous environments. This specialization gave the client confidence that their complex safety needs would be met without compromise.

• Deep knowledge of ATEX and other explosion-proof standards
• Ability to customize every component for classified zones
• Proven track record with chemical, oil, and gas industry clients
• Strong internal quality controls specifically for explosion-proof products

Experience with European Clients and Standards

Working with clients across Europe has sharpened our ability to meet strict regulations and customer expectations. The client appreciated our understanding of their market’s demands.

• Familiarity with CE certification and European safety directives
• Smooth handling of documentation required for import and installation
• Experience communicating clearly in English and German
• Ability to adapt designs to local power supplies and site conditions

Strong Engineering and After-Sales Support

Our team provided proactive engineering guidance throughout the project, from initial design to commissioning. The client valued the ongoing support after delivery as well.

• Dedicated project managers ensuring smooth communication
• Flexible solutions tailored to site-specific challenges
• Remote and on-site technical support available post-installation
• Comprehensive training and detailed manuals provided

Cost-Efficiency and On-Time Delivery

Despite the technical complexity, we delivered a competitively priced crane on schedule. This helped the client avoid costly project delays and budget overruns.

• Competitive pricing without compromising quality or safety
• Efficient production processes allowing a 10–12 week lead time
• Coordination with logistics partners for timely delivery
• Transparent updates throughout manufacturing and shipping

Choosing Yuantai Crane gave the client peace of mind knowing they had a reliable partner who understood their needs and delivered a safe, high-performance crane on time and within budget.

Conclusion

This project was a clear success from start to finish. The 40-ton explosion-proof overhead crane met all the client’s technical and safety requirements and was delivered on time without issues.

The crane has already added significant long-term value to the German client’s operations. It enhanced workplace safety, improved lifting precision, and boosted overall production efficiency in a challenging hazardous environment.

Yuantai Crane once again proved its expertise in designing and delivering reliable explosion-proof lifting solutions tailored to demanding industrial needs. Our commitment to quality, compliance, and customer support makes us a trusted partner for clients worldwide.