Description

Al Waha Cranes proudly delivered a custom-engineered 5 Ton Single Girder Overhead Crane with a remarkable 37-meter span to a prominent industrial client in Abu Dhabi, UAE. This installation exemplifies Al Waha’s capability in delivering tailored crane solutions that meet both structural and operational demands. The crane was engineered, fabricated, and installed within a fast-track timeline, with a core focus on maximizing bay coverage without compromising performance or safety.

With its exceptionally long-span single girder structure, this crane installation stands out in the regional market, offering smooth operation, high safety margins, and intelligent controls designed for precise, repetitive tasks. Designed to meet Class A5 duty classification, the crane guarantees long fatigue life and high-load reliability, making it ideal for continuous industrial operations in the MENA region.

Successful Complete project

This milestone project is part of Al Waha Cranes’ expanding portfolio in delivering heavy-duty, custom-span lifting systems across the UAE and Saudi Arabia. The successful completion of this 5T x 37m span crane installation represents:

• A technical triumph in single girder engineering, exceeding typical span limitations.
• A demonstration of Al Waha’s end-to-end project execution, from design and structural analysis to final commissioning.
• A solution designed around site constraints, ensuring optimal hook coverage without requiring major infrastructure modifications.
• Compliance with UAE’s latest safety and crane operation standards, offering our client peace of mind and long-term reliability.

The crane was commissioned and handed over within 6 weeks — a feat made possible by Al Waha’s integrated in-house engineering, fabrication, and field teams. The customer, an EPC contractor in the Oil & Gas sector, needed rapid deployment to align with new process lines coming online. Our quick response ensured the client met their operational deadlines without compromising safety or structural integrity.

Problem

The client was expanding operations in Abu Dhabi and faced a key operational bottleneck:

• Need for extended bay coverage: Their existing layout required a crane that could cover an unusually long span without moving support columns.
• Time-sensitive project kickoff: They needed the crane commissioned within a narrow 6-week window to align with equipment delivery and production schedules.
• Space optimization constraints: Traditional dual girder systems would have increased structural load and needed infrastructure upgrades.
• Safety and compliance: The crane had to meet UAE regulatory standards and internal HSE compliance protocols of the Oil & Gas industry.

The combination of time pressure, engineering challenge (long span, single girder), and compliance requirements made this project complex.

Solution

Al Waha Cranes proposed a custom-designed, 5 Ton Single Girder Overhead Crane with 37-meter span, built around Street Crane’s A5 classification standards. This allowed us to ensure durability and fatigue resistance — critical in long-span crane structures.

Key Aspects of the Solution:

• Custom Long Span Engineering: The girder was optimized using finite element analysis (FEA) to withstand fatigue stresses over a 20+ year lifecycle. The solution reduced weight without compromising stiffness.
• Street Crane Hoisting System: Equipped with A5-class hoisting and trolley mechanisms designed for repetitive lifting, high usage cycles, and smooth load handling. It offers advanced braking, overload protection, and soft start/stop motion.
• Smart Design for Hook Coverage: The layout was engineered to maximize hook travel from end to end, offering full coverage of the client’s bay area without extra steel structure.
• Corrosion-Resistant Coating: To protect against the humid, saline environment of Abu Dhabi’s industrial zones, the entire structure was treated with marine-grade paint and anti-rust coating.
• Integrated VFD and Safety Features: VFD-enabled smooth motion, sway control, and enhanced safety through anti-collision systems and emergency stop integration.
• Local Compliance: All components and structure meet or exceed ISO, FEM, and local OSHA standards.

The final design exceeded expectations — offering superior lifecycle performance, reduced wear and tear, and significantly lower maintenance overhead.

Process

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Al Waha’s ability to execute a complex crane project in record time is powered by our fully integrated design-build-install model. Here’s how this project came to life:

1. Consultation & Site Survey

Our engineering team conducted a detailed site analysis to understand structural constraints, bay width, workflow, and support system limitations. Based on load travel maps, we identified the ideal crane type and span for full area coverage.

2. Engineering & Design

Using CAD and simulation tools, we created:

• Load-bearing structure layouts
• Fatigue cycle simulations based on projected usage
• FEM classification validation for A5 duty cycle
• Hook approach optimization and load path planning

The design was reviewed by both Al Waha’s internal QA and the client’s technical team before fabrication.

3. Fabrication

The girder was fabricated in-house at Al Waha’s facility. Key features:

• Precision-welded girder structure to minimize camber and deflection.
• Hoist and trolley assembled using Street Crane OEM components.
• Factory-level load and performance testing to pre-validate all stress points.

4. Installation & Testing

Installation was completed in less than a week with zero interruptions to the client’s other operations. Our on-site team:

• Conducted alignment, rail fitting, and electrical integration
• Ran load testing up to 125% of rated capacity
• Calibrated safety systems and limit switches

5. Commissioning & Training

Before handover:

• We trained site operators on proper usage and safety protocols.
• Supplied a full operations manual and maintenance checklist.
• Completed compliance documentation as per UAE legal standards.

Summary

This project highlights Al Waha Cranes’ unmatched ability to engineer and deliver customized overhead lifting solutions under pressure — both in terms of timeline and technical complexity. By focusing on fatigue cycles, structural design classification, and rapid deployment, Al Waha once again proves to be the crane partner of choice for mission-critical applications in the UAE.

Whether you need long-span single girder cranes or complex multi-hoist systems, Al Waha is the name that lifts industries.