For a single rotating reach at a fixed pivot, a jib crane is the more compact alternative to a workstation system. Workstation cranes pair naturally with electric chain hoists matched to the duty cycle.
Mount configurations and track materials
Mount configuration is driven by your building structure, whether your floor is loadable, and how often you'll relocate the system. Track material (cold-rolled steel or anodised aluminium) is driven by capacity, span and how long the operator is on the tool each shift. We engineer-specify both for your facility.
Free-standing (floor-mounted)
Runway supported on floor-mounted steel columns, with no building structure required. The single biggest reason this is the most-installed configuration in Australia: your roof structure doesn't need to take any of the load. Ideal for new facilities, leased buildings where you can't load the structure, or shops where the roof trusses won't take the suspended weight.
- Capacity: 125 kg to 2,000 kg MRC
- Span: up to 14 m
- Foundation: concrete C30 with thickness ≥ 150 mm
- Modular: increase, decrease or relocate in line with process changes; the rest of the system keeps running
Underslung (suspended from building structure)
Runway suspended from the building's roof structure: light steel grid, concrete bearing beam, purlins, or a column corbel. More space-efficient than floor-mounted because there are no columns interrupting the floor. Requires a structural assessment of the support points; we include this as part of the specification.
Cold-rolled steel track
The default for general manufacturing up to 2 t MRC. Cold-rolled high-strength steel formed in a single pass with no welding or heat-affected zones: stronger than aluminium for the same profile, longer permitted suspension spacing, lower cost per metre. Suits intermittent and continuous duty across the full capacity range, in steel-mill, fabrication, automotive and warehousing applications.
Anodised aluminium track
The ergonomic choice within 2 tonnes where the operator is on the tool for a full shift. Anodised aluminium runway with rigid steel-to-track connection. The surface oxidation is wear-resistant and the trolley pushes lighter than the equivalent steel section. Equipped with secondary protection mechanisms between track and steel structure for higher safety. Pairs naturally with electric chain hoists, intelligent lifting devices and rigid-arm clamp end-effectors.
Track engineering: why rigid beats I-beam
The track itself is what makes a workstation crane work. Specified poorly, it sags, jams, and binds on the trolley.
- Cold-rolled high-strength steel track: formed in a single pass, no welding, no heat-affected zone, no deformation over service life.
- Enclosed C-section profile: keeps dust out of the running surface; reduces wheel wear and extends trolley life.
- 2° bevel design at the track opening: auto-centres the trolley at the middle of the rail, drops sliding resistance and stops the trolley wandering.
- Rigid connection between modules: does not produce diagonal-pulling that you get on flexible-cable suspended systems; positioning is more accurate, less sloshing.
- Lifting-point spacing up to 9 m: fewer suspension points means fewer columns or fewer roof tie-ins, cleaner shop layout.
- I-beam suspension not required: the track is structural in itself; the dead-weight load on the supporting structure is reduced compared to an equivalent I-beam monorail.
Capacity range
| Standard MRC steps | 125 kg · 250 kg · 500 kg · 1,000 kg · 1,500 kg · 2,000 kg |
| Span (bridge) | Up to 14 m |
| Suspension spacing | Up to 9 m between support points |
| Lift height | Building-clearance limited; typically 2.5 m – 5 m under hook |
| Track materials | Cold-rolled high-strength steel · anodised aluminium alloy |
| Standards | AS 1418.1 · AS 1418.3 · AS 2550 |
Push force at rated load
Manual travel is generally suitable for lighter loads and short travel distances. For frequent operation, longer travel, or capacities above 1 tonne, powered travel is recommended to improve ergonomics and operator control.
| Rated load | Manual push force at rated load | Powered traverse operator input |
| 125 kg | 1.0 – 2.0 kgf | ≤ 1 kgf |
| 250 kg | 2.5 – 4.5 kgf | ≤ 1 kgf |
| 500 kg | 5 – 9 kgf | ≤ 1 kgf |
| 1,000 kg | 10 – 18 kgf | ≤ 1 kgf |
| 1,500 kg | 15 – 25 kgf | ≤ 1 kgf |
| 2,000 kg | 20 – 32 kgf | ≤ 1 kgf |
Values are indicative only and assume a level runway, clean track, correctly aligned system, suitable wheels/rollers, good bearings and rated load conditions. Actual push force may vary depending on span, bridge weight, trolley type, wheel condition, alignment, load position and site conditions. For frequent movement above 1,000 kg, powered travel is recommended.
Drive options
- Manual push: standard for smaller cells; relies on the low track friction to keep operator effort low.
- Electric drive (frequency-conversion / VFD): recommended above 1 t MRC or above 7.5 m track spacing. Smooth start/stop, accurate positioning, lower brake wear.
- Power supply: festoon cable or sliding contact (conductor) bar.
Hoist options
- Electric chain hoist: the standard answer for repetitive lifting. Duty-rated motor, electromagnetic disc brake, overload clutch.
- Manual chain block: for occasional lifts under 500 kg.
- Intelligent lifting device: servo-driven assist with stepless speed control, software soft-limits, overload alarms and palletising/auto-suspension modes. Useful where positioning precision matters more than throughput.
- Rigid-arm clamp / end-effector: for parts that don't take a hook (panels, sheets, awkward components).
Industry adaptations
The base specification covers most general manufacturing. Where the environment is more demanding, the track and the ancillaries are upgraded accordingly.
- Food & pharma: food-grade stainless steel 304 or 316L track and components; stainless fasteners; food-safe lubricants.
- Explosion-proof: Ex-rated electrical equipment for Zone 1 / Zone 2 environments per AS/NZS 60079.
- Anti-corrosion: galvanised or polyurethane-finished steel components for coastal or chemically aggressive environments.
- Curved rail / turnouts: non-linear runway geometry where the production flow demands it.
- Clean-room compatible: low-particulate finishes and sealed bearings.
Why workstation cranes earn their place
- Lower building cost. No corbel or column-grid modification needed for the structure. Free-standing systems carry their own load.
- Retrofittable. The system can be added to an existing workshop without modifying the building.
- Modular. Increased, decreased or relocated as the production line changes, while the rest of the system keeps running.
- Quiet. Smooth track surface and special trolley design give minimal running noise and no operator fatigue from repeated noise exposure.
- Energy-efficient. Powered systems use roughly 80 % less energy than equivalent overhead bridge cranes for the same lift work.
- Low maintenance. The track system is essentially maintenance-free; electrical components are simple and accessible.
Example applications
The examples below are indicative of the configurations we engineer. They illustrate capacity, span and duty, not a record of completed installations. Every crane is sized from your own site and duty cycle.
- Laser-cutting facility: 1 t ceiling-mounted LCS for sheet handling across a 9 m × 9 m work area.
- Engine reconditioning workshop: floor-mounted 500 kg cell for engine removal and reinstallation.
- Packaging line: 250 kg underslung monorail for carton loading.
- Metal fabrication shop: 1 t free-standing aluminium LCS for positioning steel plate.
- Welding workshop: 1,000 kg free-standing rigid-track system replacing flexible enclosed-track runs that were rejected for the dust-heavy environment.
- Machining centre feeding: 125 kg free-standing rigid crane paired with an intelligent lifting device for ~45 kg parts at 20+ cycles per day.
Frequently asked questions
Steel rail or aluminium rail — which should I specify?
Cold-rolled steel track is the default for general manufacturing up to 2 t MRC: stronger, longer permitted spans, lower cost per metre. Aluminium alloy track wins where the operator is on the tool for a full shift and push-force matters: it's lighter, the anodised running surface is wear-resistant, and the trolley pushes noticeably easier. Steel covers most cases; aluminium pays back where ergonomics is the constraint.
What's the maximum capacity for a workstation crane?
Standard MRC steps run 125 kg, 250 kg, 500 kg, 1,000 kg, 1,500 kg and 2,000 kg. Above 2 t the rigid-track architecture stops being the right answer, and we'd recommend an EOT bridge crane instead. Spans up to 14 m with suspension points up to 9 m apart are possible at the higher capacities, subject to building structure or floor design.
Are workstation cranes designed to AS 1418?
Yes. Sorian workstation crane systems are designed to AS 1418.1 (general crane requirements) and AS 1418.3 (bridge, gantry, portal and jib cranes), with operation and inspection regimes per AS 2550. Every system is supplied with engineering calculations, a compliance statement, an O&M manual and a load-test record. Where the system is rated above the relevant state thresholds, WorkSafe design registration is managed as part of the project.
Can a workstation crane be expanded later?
Yes: modularity is one of the main reasons people choose workstation cranes over fixed monorails. Bridges and runways can be lengthened, additional bridges added on the same runway, suspension points relocated, and entire cells reconfigured as the production line changes, typically without taking the rest of the system out of service. Specify the runway one size larger than today's plan and future expansion is a half-day job, not a redesign.
Floor-mounted (free-standing) or ceiling-mounted (underslung) — which is right?
Free-standing is the default in Australia: the system carries its own load on floor-mounted columns, your roof structure takes nothing, and it works in leased premises and lightweight buildings. Choose underslung when you need maximum floor area (no columns), the building structure has been confirmed by structural assessment to take the suspended load, and the roof tie-in is feasible. We engineer-specify the right configuration based on your actual building, not a default.
Workstation cranes by city
Workstation cranes (also known as light crane systems) come in three Australian-supplied city set-ups. See also the light crane systems pillar page for the full national overview.
Workstation cranes Brisbane: modular enclosed-track light crane systems for mining services, food processing, defence and metal fabrication across Acacia Ridge, Wacol, Rocklea and Pinkenba. Mining-services workshops typically need 1–2 t freestanding systems in cold-rolled steel for general workshop assembly; Rocklea food processors favour stainless-track variants with washdown-rated ancillaries; Pinkenba defence subcontractors run aluminium-track cells where operators are on the tool for full shifts. Modular layouts allow expansion as production lines change.
Workstation cranes Melbourne: modular enclosed-track light crane systems for advanced manufacturing, automotive and food processing across Truganina, Dandenong, Campbellfield and Hallam. Advanced manufacturing in Truganina and Laverton typically runs 1–2 t aluminium-track cells for press tending and sub-assembly; automotive workshops in Dandenong and Campbellfield use steel-track systems for engine and EV battery handling; food processors in Hallam and Truganina specify stainless variants. Aluminium track is the ergonomic choice where the operator is on the tool for full shifts.
Workstation cranes Sydney: modular enclosed-track light crane systems for defence, advanced manufacturing and food processing across Bankstown, Wetherill Park, Smithfield and Eastern Creek. Bankstown defence and aerospace cells typically need precision 0.5–2 t aluminium-track for full-shift assembly; Wetherill Park and Smithfield manufacturing favours steel-track systems for general production cells; Eastern Creek and Auburn food processors specify stainless variants for washdown environments. Modular spans up to 14 m fit most brownfield Sydney workshops without structural modification.