Explosion-Proof Overhead Crane
Flammable and explosive environments
Mongolia
Of all the Explosion-Proof Overhead Crane export projects we have handled over the years, this one in Mongolia is a classic example of three challenges coming together: explosion protection, extreme cold, and tight cost control. The customer needed an Explosion-Proof Overhead Crane with specific explosion-protection and ingress-protection ratings. Local winter temperatures can fall to -35°C, with wide temperature swings between day and night, and the budget was also limited.
In the end, we met all these requirements with two 10-ton LB Single Girder Explosion-Proof Overhead Cranes. From crane selection and technical discussions to packing and shipment, the complete cranes cost around 30% less than a European-style explosion-proof solution and reached Mongolia by road in eight days. Here is how we brought the project together.
The Mongolian Customer's Key Challenge
First, a little background. The customer operates a factory in Mongolia where flammable and explosive hazards may be present. An ordinary electrical system was not an option for the workshop cranes, the complete system had to be explosion-proof, and safety was non-negotiable. The customer already had a clear technical specification: a 10-ton capacity, a 22.5 m span, an 18 m lifting height, and an AT3 explosion-protection rating. They were looking for a manufacturer that could provide the required explosion protection and enclosure protection at a reasonable price.
The main challenges of this project were:
- The first was the explosion-protection and ingress-protection ratings. The customer initially specified an AT3 rating for the Explosion-Proof Overhead Crane, along with Schneider Electric components, IP55 motors, and IP65 control-box enclosures. These were demanding requirements. A standard LB Bridge Crane comes with IP44 protection, so supplying the standard configuration would not have met the customer's needs.
- The second was the extreme cold. Winter temperatures in Mongolia frequently drop to -35°C, and the temperature difference between day and night is significant. Under such conditions and repeated thermal cycling, the durability of the steel structure, electrical components, and paint system becomes a genuine concern. Cracking or peeling paint and brittle seals are common problems in low-temperature environments.
LB Overhead Crane or European-Style Overhead Crane? About 30% Saved Without Sacrificing Performance
At the beginning, we offered the customer two options: an LB explosion-proof single-girder crane and a European-style explosion-proof single-girder crane. Both could meet the essential specifications of a 10-ton capacity, 22.5 m span, and 18 m lifting height. The main differences were the structural design, deadweight, and price.
The European-style design is more compact. For this project, however, the customer's real priorities were reliable explosion protection, compliant enclosure protection, dependable operation, and a sensible price—not the lightest possible structure. When the two quotations were compared side by side, the complete LB Overhead Crane was about 30% more affordable.
After comparing the options, the customer chose the LB Overhead Crane. This reflects a principle we follow in international projects: our job is not to sell the most expensive crane, but to help each customer choose the one that fits best.
How We Customized the Explosion-Proof Overhead Crane?
Technical Specifications
Once the solution was selected, the real work was turning every special requirement into drawings and production details. The final crane specifications were as follows.
- Capacity: 10 Ton
- Span: 22.5 m
- Lifting Height: 18 m
- Explosion Protection: Exd II BT4
- Power Supply: 380V, 50Hz, 3 Phase
- Control Method: Wireless Remote Control
- Quantity: 2 Sets
Five Custom Features for the Mongolia Crane Project
- First came the explosion-protection rating. The customer initially requested AT3, while our factory starts at BT3. Both share the T3 temperature class, limiting the equipment's maximum surface temperature to 200°C. However, IIB covers medium-hazard gases and is compatible with lower-hazard IIA environments, so BT3 can replace AT3. After reviewing the actual working conditions with the customer, we supplied the crane with the higher Exd II BT4 rating for added safety. Explosion-proof motors, a control box, push buttons, and the required certificates were all included. Clear confirmation of these details early on helps prevent on-site mismatches and costly rework.
- Electrical configuration: Schneider Electric throughout. The customer specified the electrical brand, so we equipped the complete crane with Schneider Electric components. This supports stable performance and makes compatible replacement parts easier to source—an especially important advantage for overseas customers who may need to find parts locally in the future.
- Ingress protection: upgraded from standard IP44 to IP55 for the motors and IP65 for the control-box enclosures. These changes were made specifically for the customer's operating requirements. Sealing, wiring, and cable-entry details were also adjusted to provide sufficient protection for the actual working environment.
- Control method: wireless remote control. The Explosion-Proof EOT Crane is operated by wireless remote control and uses a 380V / 50Hz / three-phase power supply. In an explosion-risk workshop, operators can maintain a safe distance from the equipment while enjoying greater flexibility during operation.
- Painting: a coating system reviewed for extreme cold down to -35°C. The total dry film thickness was controlled at 70–130 microns, with phenolic red iron oxide anti-rust primer and an alkyd topcoat. Considering Mongolia's -35°C winters and wide day-to-night temperature swings, we paid extra attention to steel-surface preparation, rust-removal grade, and coating uniformity. Poor paint adhesion, cracking, and peeling during thermal cycling are major risks in low-temperature service. Thorough preparation and stable film thickness help the coating withstand Mongolia's severe cold.
Weatherproof Wrapping, Wooden Cases, and 8-Day Road Delivery
Mongolia is landlocked, so the Explosion-Proof Overhead Cranes were shipped by road. The packaging therefore had to withstand long-distance overland transport as well as possible storage after arrival.
We wrapped the main steel structures in waterproof sheeting to protect them from rain and dust during transport. Precision and vulnerable components, including the electrical cabinets and hoists, were packed separately in wooden cases, with an additional inner layer of protective film. Both cranes were securely fixed and properly cushioned before loading. The road journey to Mongolia took eight days. We also kept a complete photographic record of the packing and shipment so the customer could check the condition of the cargo against the photos upon arrival.
Explosion-Proof Overhead Crane Delivery Results
Both 10-ton LB Single Girder Explosion-Proof Overhead Cranes were manufactured and shipped successfully according to the customer's approved specifications: Exd II BT4 explosion protection, Schneider Electric components, IP55/IP65 protection, and wireless remote control. The explosion-proof certificates and production drawings were supplied with the cranes, which reached Mongolia after eight days of road transport.
From comparing crane designs and upgrading the protection ratings to preparing the coating for extreme cold and arranging inland logistics, we helped the customer find the right balance. Costs were reduced while the two priorities that mattered most—explosion-protection compliance and reliable performance in extreme cold—were fully addressed.
Let's Talk About Your Explosion-Proof or Cold-Climate Crane Project
If you are working on a similar project, whether you need compliant explosion protection, a crane built for extreme cold or high-salt environments, or a more cost-effective solution without compromising your technical requirements—we would be glad to discuss it with you, wherever your project is located. NUCLEON engineers will evaluate your actual working conditions and hazardous-area classification, then provide a one-to-one crane selection proposal and quotation.
I am Novia, engaged in crane export for 10 years, serving customers in 20 countries. I have a reserve of professional knowledge about the structure and performance of various types of cranes. From quotation to design plan to delivery, I will provide you with one-to-one service to provide you with the most cost-effective and professional crane solution. If you need to buy a crane, please contact me for the latest service.
