Explosion-Proof Overhead Crane
Flammable and explosive environments
Mongolia
We have been exporting explosion-proof overhead cranes for years, and this Mongolia project is a great example of balancing explosion protection requirements with cost control.
The customer was looking for an explosion-proof overhead crane for their factory in Mongolia, with strict requirements for explosion-proof performance and enclosure protection. At the same time, the project budget was limited, so they needed a solution that could meet safety standards without adding unnecessary costs.
In the end, we delivered two 10-ton LB Single Girder Explosion-Proof Overhead Cranes that successfully met all these requirements. From solution design and technical discussions to production, packing, and shipment, the complete crane system was around 30% more cost-effective than a European-style explosion-proof solution and arrived in Mongolia by road transport within 8 days.
In this case, I will walk you through how we approached this project and how we developed the final solution.
Key Challenges of the Mongolian Project
First, let's look at the customer's actual situation. This was a factory in Mongolia operating under conditions with potential flammable and explosive hazards. The cranes used in the workshop could not rely on standard electrical configurations—the entire system had to be designed with explosion-proof protection. Safety was the top priority and there was no room for compromise.
The customer already had a clear technical specification: 10-ton lifting capacity, 22.5 m span, 18 m lifting height, and an AT3 explosion-protection requirement. Their needs were straightforward: they were looking for a manufacturer that could provide reliable explosion-proof performance, meet the required protection levels, and offer a reasonable price.
The key challenges of this project were:
- The first challenge was the explosion-protection and ingress-protection requirements. The customer initially required an AT3 explosion-protection rating for the Explosion-Proof Overhead Crane, along with Schneider Electric components, IP55 motors, and IP65 control box enclosures. These requirements set a relatively high technical standard for the equipment.
- The second challenge was how to control the project budget while meeting the explosion-proof performance requirements. For explosion-proof cranes, the cost difference is not only determined by lifting capacity or crane structure. Explosion-proof motors, explosion-proof electrical enclosures, special wiring protection, explosion-proof certifications, and customized protection measures all add additional costs. This is also one of the main reasons why explosion-proof equipment is generally more expensive than standard cranes.
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
Four Custom Features for the Mongolia Crane Project
1. First came the explosion-protection rating: The customer initially requested an AT3 explosion-proof rating, while NUCLEON's explosion-proof crane products start from the BT4 level as standard. During the technical review, we further explained the differences between the various explosion-proof classifications to help the customer better understand the protection levels.
In explosion-proof equipment classification, A and B represent gas groups, while T3 and T4 represent temperature classes. They are two different evaluation criteria.
The gas group indicates the type of explosive atmosphere the equipment is designed for:
- IIA: Suitable for flammable gas environments with relatively lower hazard levels.
- IIB: Suitable for medium-risk flammable gas environments, with higher protection requirements than IIA.
Simply put, IIB equipment can be used in IIA environments, but IIA equipment cannot replace IIB equipment.
The temperature class defines the maximum surface temperature allowed during equipment operation:
- T3: Maximum surface temperature ≤200°C
- T4: Maximum surface temperature ≤135°C
Compared with T3, T4 requires a lower operating surface temperature, further reducing the risk of igniting surrounding flammable gases. Therefore, T4 provides a higher level of temperature protection.
After reviewing the actual working conditions with the customer, we finally supplied the crane according to the higher safety standard, adopting an Ex d II B T4 flameproof protection design. The final delivered equipment was an LB Explosion-Proof Overhead Crane, equipped with explosion-proof motors, explosion-proof control boxes, explosion-proof push buttons, and complete explosion-proof certification documents.
The biggest challenge in an explosion-proof project is not the complexity of the technical parameters, but whether the requirements are fully understood at the beginning. If the explosion-proof rating, gas group, and temperature class are not clearly confirmed in advance, it can easily lead to equipment mismatches, certification issues, or even costly rework at a later stage.
Therefore, confirming these details before production is a crucial step to ensuring the successful delivery of the project.
2. Electrical configuration: The customer specified Schneider Electric components for the electrical system, and we configured the entire crane with Schneider electrical components accordingly. This not only improves overall system stability but also ensures better compatibility and convenience for future maintenance and spare parts replacement.
For overseas customers, this is especially important. In case any electrical components need to be replaced in the future, globally recognized brands like Schneider Electric are easier to source locally, helping reduce maintenance difficulties and minimize potential downtime.
3. Ingress protection: The NUCLEON LB Explosion-Proof Single Girder Overhead Crane comes standard with IP55 motors and IP65 control box enclosures, which perfectly match the customer's protection requirements without requiring any additional upgrades.
By using the standard configuration, the crane not only meets the required protection level but also helps reduce unnecessary extra costs. This allowed us to provide a reliable explosion-proof solution while maintaining better cost efficiency for the project.
4. Control method: 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.
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.
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
The two 10-ton LB Explosion-Proof Single Girder Overhead Cranes were successfully manufactured and shipped according to the customer's confirmed technical requirements. The final configuration included an Ex d II B T4 explosion-proof rating, Schneider Electric components, IP55/IP65 protection levels, wireless remote control, complete explosion-proof certificates, and production drawings. The cranes were delivered to Mongolia by road transportation within 8 days.
From solution comparison and protection upgrades to inland logistics arrangements, we helped the customer find the right balance between safety, performance, and cost efficiency. The project not only reduced unnecessary investment but also ensured that the customer's most important concern—explosion-proof compliance and operational safety—was fully achieved.
Let's Talk About Your Explosion-Proof Overhead Crane Project
If you have a similar project that requires explosion-proof compliance or you are looking for ways to reduce costs while still meeting safety requirements, feel free to contact us for discussion, no matter where your project is located.
NUCLEON's engineers will evaluate your actual working conditions, hazardous area classification, and technical requirements to provide a one-on-one crane selection solution and quotation tailored to your application.
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.
