Monorail Crane Systems

What does a monorail crane system include?

In a monorail hoist project, the hoist is only one part of the job. Safe operation also depends on the beam, the hangers and the power line being installed correctly. A complete system covers these items together:

• Beam: An I-beam such as NPI, IPE or HEA/HEB. The trolley runs on its bottom flange.
• Hangers and support structure: They connect the beam to ceiling girders, columns or a freestanding steel structure. The whole load passes through them into the building.
• Hoist and trolley: A chain or wire rope hoist with a motorised or manual trolley. Two hoists can be fitted to the same beam to lift long parts at two points. In that case the beam and hangers are calculated for the combined load of both hoists.
• Power supply: The system that carries power to the hoist as the trolley travels. On short and medium runs, cable festoon systems are usually used.
• Safety parts: End stops at the beam ends, lifting and travel limit switches, and a pendant with an emergency stop.

System types

• Monorail crane system: A single beam line. The beam can be straight, curved or fitted with switches. The load follows the same route every time.
• Bridge monorail systems: A bridge girder that travels on parallel beam lines is added, and the hoist works on this bridge. The load is then carried over a rectangular area instead of along a single line.
• Monorail gantry system: The beam sits on its own frame with legs instead of hanging from the ceiling. It is used to set up a lifting line without putting load on the building, or outdoors. For mobile models, see gantry cranes.

Where are they used?

They are useful anywhere loads are moved along the same route again and again. The most common uses are moving parts between stations on production and assembly lines, moving moulds between presses, moving goods from the loading bay to the storage area, and carrying hanging parts through paint shops and blasting lines.

Hoist only, or a complete system?

If your site already has a suitable beam, a hoist on its own is often enough. In that case see our monorail chain hoists, or monorail wire rope hoists for heavier loads and higher lifts. If there is no beam, if the existing beam does not suit the capacity of the new hoist, or if the line is to be extended, the track system is designed from scratch. When the beam, hangers, hoist and power supply are planned by one team, the parts fit together. We explain monorail types and parts in our guide what is a monorail hoist?

Information needed to design the system

1. Load: The heaviest load, including slings and attachments.
2. Lifting height: The distance the hook travels up and down.
3. Beam route: The length of the line and any curves or switches. A sketch with dimensions is enough.
4. Structure the beam hangs from: Ceiling girder, roof truss, column or freestanding structure. You must always check whether the existing structure can carry the extra load.
5. Trolley and power: Motorised or manual? Industrial hoists need 400 V three phase power. How power runs along the beam is planned from the start.
6. Duty: How many hours a day the system works and how many lifts it makes.

In a monorail track system, the beam size and hanger spacing are set by calculation, not by guesswork. We explain beam profiles, hanging methods and curved runs in our guide on monorail beams and installation.

Monorail crane system prices

The main factors in the price are the beam length and profile, the number and type of hangers, any curves and switches, the hoist capacity and lifting height, the trolley type, the length of the power line and the installation conditions. Just send us a sketch of your beam route, a few photos and the heaviest load on WhatsApp.

Installation, commissioning and periodic inspection

We install and service monorail crane systems from our base in Tuzla, Istanbul. After the site survey and measurements, the beam and hangers are made, the beam is hung and levelled, and the hoist, end stops and power line are fitted. The system is tried without load and with load. Before first use, an authorised person carries out an inspection and load test. After that, Turkish law requires lifting equipment to have a periodic inspection at least once a year.