Lifting is one of the most demanding and risk-intensive activities that takes place in any warehouse. Done manually, it causes more than a third of all workplace injuries in the UK, according to the Health and Safety Executive (HSE). Using the wrong equipment creates bottlenecks, damages goods and increases downtime.
The right warehouse lifting equipment changes that picture. It takes the physical strain off workers, speeds up material handling and gives operations a consistent, reliable way to move loads of all sizes.
The Metreel team are here to help explain the main types of overhead lifting equipment available and how each one fits into a warehouse environment.
Overhead Bridge Cranes
An overhead bridge crane runs on two parallel runway beams mounted to the walls or supporting structure of a building. A bridge spans those runways and carries a hoist that travels along it, giving the crane movement in three axes: along the runway, across the bridge and vertically as the hoist raises and lowers the load.
Bridge cranes suit warehouses where the same heavy loads need to be moved repeatedly across a defined floor area. They are available in single girder and double girder configurations. Single girder cranes are the more economical option for medium loads and standard spans. Double girder cranes provide greater rigidity and higher capacity for demanding applications where loads are heavier or spans are wider.
Because bridge cranes operate entirely overhead, they free up the full floor area beneath them for other activity. There are no columns or ground-level obstructions associated with the crane itself, which makes them well suited to busy warehouse floors where forklifts and personnel need room to move.
Workstation Cranes
Workstation cranes are a lighter, more ergonomic form of overhead bridge crane designed for precision handling at individual workstations or assembly areas rather than across a full warehouse span. They are typically mounted to a freestanding floor framework or to the ceiling, and they are engineered to be moved with minimal effort by the operator.
The Met-Track workstation bridge crane from Metreel requires just one per cent of the load weight to initiate movement, making it significantly easier to operate than a conventional crane under the same load. That matters in environments where the same operator is performing repeated lifts throughout a shift. Reducing the physical effort involved in each movement reduces fatigue and the risk of strain injuries over time.
Workstation cranes are available in load capacities from 125kg to 2,000kg and can be configured with a range of lifting devices including manual hoists, electric hoists, vacuum handlers and manipulators. The modular design allows the system to be extended or relocated without major structural work, which is useful where warehouse layouts change as operations evolve.
Jib Cranes
A jib crane consists of a horizontal boom arm mounted to a wall, column or floor-mounted mast. The hoist travels along the boom, and the boom itself rotates to give the crane its working arc. Floor-mounted jib cranes offer full 360-degree rotation. Wall-mounted versions typically cover 180 degrees.
Jib cranes are the practical choice for localised lifting tasks where a full bridge crane would be disproportionate. A machine loading cell, a goods-in bay or a maintenance area with regular lifting requirements are all typical applications. The crane serves a defined zone around its mounting point without interfering with the wider warehouse floor.
Metreel manufactures both floor-mounted and wall-mounted jib cranes, with bespoke options available for applications where standard configurations do not fit the space or load requirement. Outdoor-rated versions with weather protection can also be specified for yard and external loading areas.
Gantry Cranes
A gantry crane operates on the same principle as a bridge crane but is supported by freestanding legs rather than fixed runway beams. The legs run on wheels or rails at floor level, making gantry cranes independent of the building structure and repositionable without significant installation work.
That portability makes gantry cranes a practical option in warehouses or workshops where overhead infrastructure cannot support a fixed crane, or where lifting requirements move around the facility. They are equally suited to outdoor use in yards and loading areas.
Metreel’s AluLift aluminium gantry cranes are built from high-grade aluminium rather than steel, which makes them substantially lighter without sacrificing load capacity. The range covers lifting capacities from 500kg to 2,000kg with spans of up to six metres. Each system is supplied complete with a load trolley and can be assembled and broken down without specialist tools.
Hoists
A hoist is the lifting component that attaches to a crane, monorail or fixed beam to raise and lower loads vertically. It is the part of the system that does the actual lifting, as distinct from the crane structure that provides horizontal movement.
Hoists are available in manual and electric versions. Manual chain hoists are a simple, low-cost option for occasional lifts where power supply is limited or where the load is light enough to be manageable by hand. Electric hoists offer greater speed, higher capacity and reduced operator effort, making them the standard choice in production and warehouse environments where lifting is frequent.
The choice of hoist affects the overall performance of any crane system. Factors including safe working load, lift height, lift speed and duty cycle all need to be matched to the application to ensure the system performs reliably over its working life.
Monorails
A monorail system runs along a single overhead track and carries a hoist or lifting device along a fixed path. Unlike a bridge crane, the load can only travel the route of the track rather than across a two-dimensional floor area. That constraint is actually an advantage in applications where loads need to follow a consistent, repeatable path.
Monorails are well suited to production lines where components need to move between workstations in sequence, and to warehouses where goods follow a defined route from goods-in to storage or dispatch. Metreel’s monorail systems can be configured with curves, switches, turntables and other track features to handle complex routing requirements within a facility.
Need Help Choosing The Right Warehouse Lifting Equipment?
The correct equipment for a warehouse depends on a combination of factors. Namely, the maximum load weight to be lifted, the span and height available, the frequency and nature of lifts, whether the application is indoor or outdoor and whether the installation is to be permanent or temporary.
A high-throughput production environment moving consistent loads along a fixed path calls for a different solution from a maintenance workshop with occasional, varied lifts. Getting that match right from the outset avoids the cost of replacing undersized or unsuitable equipment later.
Metreel works with businesses across the UK to specify, manufacture and install overhead lifting solutions across all the equipment types covered in this guide.
To discuss your requirements, please send us a message or give us a call on 0115 932 7010.