Transportation of Large Industrial Equipment: Lifting, Securing, and Route Planning for Cargo Over 10 Tons

Large industrial equipment weighing over 10 tons—such as heavy-duty machine tools, chemical reactors, wind turbine main shafts, and mining crushers—are core assets for industrial production and engineering construction. Due to their characteristics of “excessive width, overweight, and precise structure,” their transportation requires breaking through the technical barriers of conventional logistics. According to data from the China Heavy Machinery Industry Association, in 2024, accidents in the transportation of large industrial equipment in China caused by lifting errors, improper securing, and route adaptation deviations accounted for 28%, 35%, and 22% respectively, resulting in direct economic losses exceeding 500 million yuan. Focusing on the three cores of “safe lifting, reliable securing, and route adaptation,” this article breaks down the full-process technical key points for transporting large industrial equipment over 10 tons, providing actionable operation plans for relevant enterprises.

I. Lifting: The “First Gateway” for Equipment Over 10 Tons—Precise Selection and Standardized Operation Are Core

Lifting is the first critical link in transferring large industrial equipment from factory workshops to transport vehicles. It needs to address three issues: “equipment load adaptation, precise lifting point positioning, and operational safety protection” to avoid risks such as equipment collision and falling.

(1) Selection of Lifting Equipment: Following the “1.5-Time Safety Margin” Principle

Lifting equipment for equipment over 10 tons must be selected based on the equipment’s weight, external dimensions, and structural strength. The core is to ensure that the rated load of the lifting equipment is more than 1.5 times the actual weight of the equipment to avoid “overload lifting”:

• Equipment of 10–20 Tons: Priority is given to 25–30 ton truck cranes (e.g., XCMG QY25K5C truck crane with a rated load of 25 tons), matched with 16–20 ton synthetic fiber slings (to avoid scratching the equipment surface). For example, when lifting a 15-ton heavy-duty machine tool, a 25-ton truck crane is used, and the length of the sling is adjusted according to the equipment height (usually 6–8 meters) to ensure the equipment remains horizontal during lifting;
• Equipment of 20–50 Tons: 50–80 ton truck cranes (e.g., Sany Heavy Industry STC500E truck crane with a rated load of 50 tons) or crawler cranes (suitable for soft ground scenarios) are required. For cylindrical equipment (e.g., a 22-ton reactor), special lifting fixtures (e.g., arc-shaped spreaders) must be used to prevent the sling from slipping;
• Equipment Over 50 Tons: All-terrain cranes with a rated load of over 100 tons (e.g., Zoomlion QAY100V all-terrain crane) or combined operation of multiple cranes (e.g., two 50-ton truck cranes for “dual-crane lifting” of a 50-ton wind turbine main shaft) are required. During dual-crane lifting, it is necessary to ensure uniform load distribution between the two cranes (deviation not exceeding 10%) and synchronized operation.

Note: The use of lifting equipment with insufficient rated load is strictly prohibited. In 2023, a chemical enterprise illegally used a 25-ton truck crane to lift a 28-ton reactor, resulting in boom fracture and reactor falling damage, with direct losses of 120,000 yuan.

(2) Lifting Point Positioning and Force Calculation: Avoiding Equipment Structural Damage

Lifting points for large industrial equipment must be set strictly in accordance with the “designated lifting points” marked in the equipment manual. If there is no clear marking, they must be determined through force calculation to ensure uniform force on the equipment during lifting:

• Regular-Shaped Equipment (e.g., Rectangular Machine Tools): Lifting points are symmetrically distributed on both sides of the equipment’s center of gravity, with no fewer than 2 points. For example, for a 20-ton rectangular machine tool with its center of gravity at the equipment center, lifting points are set 0.5 meters away from the center of gravity on both sides, with each lifting point bearing a load of 10 tons;
• Irregular-Shaped Equipment (e.g., Crushers with Protruding Parts): Protruding parts (e.g., feed inlets, motors) must be avoided, and positions with high structural strength in the equipment’s main body (e.g., frame girders) should be selected as lifting points. A mining enterprise mistakenly set the lifting point on the motor housing when lifting an 18-ton crusher, resulting in motor housing deformation and maintenance costs of 30,000 yuan;
• Precision Equipment (e.g., Semiconductor Lithography Machines): Special lifting tools provided by the equipment manufacturer must be used to avoid direct lifting of the equipment body. For example, a 15-ton semiconductor lithography machine needs to be connected to the lifting holes at the bottom of the equipment through a dedicated lifting frame to ensure that the lifting force is transmitted to the equipment’s load-bearing structure rather than precision components.

Before lifting, a level must be used to check the equipment’s levelness. If the inclination angle exceeds 3°, the lifting point position must be adjusted or auxiliary lifting points added to prevent internal component displacement caused by equipment inclination.

(3) Lifting Site Safety Control: Delimiting Restricted Areas and Emergency Preparation

A three-level management system of “warning area-operation area-observation area” must be established at the lifting site to prevent irrelevant personnel from entering hazardous areas:

• Site Layout: A warning area with a radius of 10–15 meters (adjusted according to lifting height) is delimited with warning tapes, and non-operating personnel are prohibited from entering the warning area; the operation area (between the lifting equipment and the equipment placement area) must be flat and solid, with a bearing capacity not lower than the ground pressure of the lifting equipment (e.g., the ground pressure of a 25-ton truck crane is approximately 0.08 MPa, requiring the laying of steel plates or gravel cushions);
• Personnel Division of Duties: The responsibilities of “commander, operator, and observer” are clearly defined. The commander issues unified instructions (e.g., hand signals, walkie-talkies), the operator strictly follows the instructions, and the observer monitors the status of the boom, lifting points, and equipment in real time, stopping operations immediately if abnormalities are found;
• Emergency Preparation: Emergency rescue equipment (e.g., spare slings, jacks, fire extinguishers) is equipped. If the lifting point loosens during lifting, the equipment must be slowly placed on a pre-prepared buffer pad (e.g., a 50mm-thick rubber pad) to avoid equipment falling.

II. Securing: The “Key to Preventing Displacement” for Transporting Equipment Over 10 Tons—Combining Layered Reinforcement and Dynamic Monitoring

The core of securing large industrial equipment is to “prevent sliding, tipping, and vibration damage during transportation.” A layered reinforcement plan must be designed according to equipment characteristics, and dynamic monitoring must be used to ensure the securing effect.

(1) Selection of Transport Vehicles: Adapting to Equipment Dimensions and Weight

Before securing, a suitable transport vehicle must be selected to ensure that the vehicle’s load capacity matches the equipment weight and the carriage dimensions meet the equipment placement requirements:

• Equipment of 10–20 Tons: 3-axle low-bed semi-trailers (rated load 30 tons, carriage length 6–8 meters, width 2.8–3 meters) are selected;
• Equipment of 20–50 Tons: 5-axle hydraulic low-bed semi-trailers (rated load 60 tons, carriage length 10–12 meters, width 3–3.2 meters) are selected, which can adjust the carriage height hydraulically to facilitate equipment loading and unloading;
• Equipment Over 50 Tons or Oversized Equipment (e.g., 3.5-Meter-Wide Tunnel Boring Machine Components): Hydraulic modular trailers (multi-axle linkage, adjustable number of axles and wheelbase to adapt to oversized and overweight equipment) are selected. For example, a 12-axle hydraulic modular trailer with a rated load of 120 tons can carry 70-ton oversized equipment.

The vehicle carriage must be flat without protrusions or depressions. If there are welds or sharp parts, they must be ground smooth with a grinder, and anti-slip cushions (e.g., 5mm-thick rubber pads) must be laid to increase friction between the equipment and the carriage.

(2) Layered Reinforcement Plan: Comprehensive Protection from “Anti-Slip-Securing-Protection”

A layered reinforcement plan is formulated according to equipment characteristics to ensure no displacement or collision of the equipment during transportation:

• First Layer: Anti-Slip Cushion: An anti-slip cushion is laid between the carriage and the equipment, made of rubber or non-woven fabric with a thickness of 5–10mm and 100% coverage. For equipment with a smooth surface (e.g., stainless steel reactors), the anti-slip cushion surface must have raised patterns with a friction coefficient of not less than 0.6 to prevent equipment sliding;
• Second Layer: Rigid Securing:
• Lateral Securing: Steel bands (width 30–50mm, thickness 2–3mm) or steel wire ropes (diameter 16–20mm) are used for lateral securing along the equipment. The spacing between securing points is not more than 1.5 meters, and there are no fewer than 2 securing points on each side. The steel bands must be tightened with butterfly buckles with a tension of not less than 5kN;
• Longitudinal Securing: Stoppers (wooden or steel, height not less than 1/3 of the equipment height) are set at the front and rear ends of the equipment. The gap between the stoppers and the equipment is filled with buffer pads (e.g., bubble wrap) to prevent longitudinal movement of the equipment. For example, when securing a 25-ton machine tool longitudinally, the height of the front and rear stoppers is not less than 1.2 meters, and the gap between the stoppers and the machine tool is filled with 50mm-thick bubble wrap;
• Third Layer: Precision Protection: Protruding parts of the equipment (e.g., instruments, pipeline interfaces) are wrapped with wooden brackets or protected by wrapping with bubble wrap + tape; precision instruments (e.g., pressure sensors) must be removed and packaged separately for transportation to avoid vibration damage.

After securing, an “empty load test run” is required: the vehicle travels 1–2 kilometers to check if the securing points are loose and if the equipment is displaced. Any issues must be adjusted in a timely manner.

(3) Dynamic Monitoring: Real-Time Mastery of Equipment Securing Status

Internet of Things (IoT) technology is used to realize real-time monitoring of the equipment’s securing status during transportation and promptly detect abnormalities:

• Inclination Monitoring: An inclination sensor is installed at the equipment’s center of gravity, with an inclination threshold set (usually 5°). If the equipment inclination exceeds the threshold during transportation, the sensor immediately sends an alarm message to the driver;
• Vibration Monitoring: A 3-axis acceleration sensor is installed on key components of the equipment (e.g., main shaft, motor) to monitor the vibration acceleration during transportation. If it exceeds the maximum allowable vibration value of the equipment (e.g., the maximum allowable vibration acceleration of precision machine tools is 0.5g), the vehicle must slow down or stop immediately for inspection;
• Securing Point Monitoring: Tension sensors are installed at the securing points of steel bands or steel wire ropes to monitor tension changes in real time. If the tension drops by more than 20% (e.g., from 5kN to 4kN), it indicates loose securing, and the vehicle must stop to re-tighten.

In 2024, a wind power enterprise detected excessive vibration through vibration sensors when transporting a 45-ton wind turbine main shaft. It stopped in time to adjust the securing plan, avoiding damage to the internal bearings of the main shaft and reducing losses by 80,000 yuan.

III. Route Planning: The “Path Navigation” for Transporting Equipment Over 10 Tons—Combining Static Survey and Dynamic Adjustment

Route planning needs to address three issues: “physical obstacle avoidance, policy compliance, and emergency alternatives” to ensure smooth transportation of the equipment from the factory to the destination.

(1) Static Survey: Comprehensive Inspection of Route Obstacles

A full-dimensional survey of the proposed route must be conducted before transportation, focusing on inspecting four types of obstacles: “height limits, width limits, weight limits, and road conditions”:

• Height Limit Obstacles: Measure the clear height of tunnels, bridges, and height limit poles along the route to ensure it is more than 0.5 meters higher than the equipment’s transportation height (including the total height of the vehicle and equipment). For example, if the equipment’s transportation height is 4.8 meters, the clear height of tunnels along the route must be no less than 5.3 meters;
• Width Limit Obstacles: Measure the clear width of bridges, culverts, and road guardrails on both sides to ensure it is more than 0.3 meters wider than the equipment’s transportation width (including the total width of the vehicle and equipment). For example, if the equipment’s transportation width is 3.2 meters, the road clear width must be no less than 3.5 meters;
• Weight Limit Obstacles: Check the design load-bearing capacity of bridges and road surfaces along the route to ensure it is higher than the total weight of the vehicle and equipment. For example, if the total weight of the vehicle and equipment is 50 tons, the bridge load-bearing capacity must be no less than 50 tons, and the single-axle load must not exceed the maximum allowable single-axle load of the bridge (e.g., if the bridge allows a single-axle load of 13 tons, the single-axle load of a 5-axle vehicle must be controlled within 13 tons);
• Road Condition Obstacles: Inspect whether there are potholes, steep slopes (slopes exceeding 15° require detours), and sharp bends (bends with a turning radius smaller than the vehicle’s minimum turning radius require detours) along the route. Rural roads or construction sections must be surveyed on-site to avoid vehicle getting stuck.

After the survey, a “route obstacle distribution map” is drawn, marking obstacle locations and solutions (e.g., detours, temporary removal of height limit poles), and filed with the transportation department.

(2) Policy Compliance: Advance Application for Over-Limit Transportation Permits

Most large industrial equipment over 10 tons falls into the category of “over-limit cargo” (total mass exceeding 49 tons, total width exceeding 2.55 meters, total height exceeding 4 meters), requiring advance completion of compliance procedures:

• Domestic Transportation Permits: Apply to the transportation department at the place of departure for an Over-Limit Transportation Vehicle Permit 7–10 days in advance, submitting materials including: equipment weight/dimension certificate, route survey report, transport vehicle registration certificate, and lifting and securing plan. For cross-provincial transportation, an “inter-provincial over-limit transportation permit” must be applied for, and advance communication and filing with the transportation departments of the passing provinces are required;
• Special Area Passage: If the route involves urban core areas or military management areas, a “temporary passage permit” must be applied for in advance from the local public security traffic management department, and the passage time (usually 22:00–6:00 the next day) and route must be determined;
• Cross-Border Transportation Compliance: If the equipment is exported to foreign countries, the route restrictions of the destination country must be confirmed (e.g., some EU countries have a road weight limit of 44 tons, requiring split transportation), and over-limit transportation permits for the destination country must be applied for in advance to avoid detention after entry.

In 2023, a machinery enterprise transporting a 38-ton machine tool across provinces was detained at an inter-provincial inspection station for 2 days due to failure to apply for an inter-provincial over-limit permit in advance, delaying the project schedule and paying liquidated damages of 50,000 yuan.

(3) Dynamic Adjustment: Contingency Plans for Emergency Situations

Route planning must include a “main route + at least 2 alternative routes” and establish a dynamic adjustment mechanism to respond to emergency situations:

• Weather Response: Obtain a 72-hour weather forecast along the route from the meteorological department. In case of severe weather such as heavy rain, heavy snow, or heavy fog, switch to the alternative route immediately (e.g., avoid mountainous sections and choose highways);
• Construction Response: Obtain real-time route construction information through freight navigation APPs (e.g., Huochebao, Amap Freight Version). If the main route encounters road construction, activate the alternative route immediately. For example, when an enterprise transported a 20-ton crusher, the main route encountered national highway maintenance, and the alternative highway route was activated, resulting in only a 1-hour delay;
• Emergency Stop Points: Set 1 emergency stop point every 50–100 kilometers along the route (e.g., highway service areas, logistics parks). The stop points must be equipped with vehicle maintenance and equipment inspection conditions to allow timely parking for handling vehicle failures or equipment issues during transportation.

At the same time, cooperative relationships must be established with maintenance plants and rescue organizations along the route, agreeing on emergency response times (e.g., arrival within 1 hour in urban areas and 2 hours in suburban areas) to ensure rapid handling of emergency situations.

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