Haitai Crane designed and delivered a 90 ton SC Type straddle carrier to CATL’s lithium battery factory in Ningde, Fujian. The project includes an integrated explosion-proof motor, lithium battery-specific VFD drive, and PLC control cabinet as a unified electrical system. Delivery was completed in August 2025.
El HT 90 ton straddle carrier meets six core requirements for battery material handling: explosion-proof and anti-static electrical system, dust-free and corrosion-resistant construction, low-speed precision travel for electrode material protection, OPC UA and MQTT digital integration, multi-layer safety redundancy, and full compliance documentation.
Project Background: 90 Ton Straddle Carrier for CATL in Fujian, China
CATL, headquartered in Ningde, Fujian Province, is the world’s largest lithium battery manufacturer. Its production facilities handle highly sensitive materials — electrode powders, electrolyte solvents, and assembled cell modules — that require strict environmental controls throughout the material handling process. In early 2025, CATL issued procurement requirements for heavy-duty internal transport equipment serving its cathode material and cell assembly workshops.
- Customer: CATL (Contemporary Amperex Technology Co., Limited)
- Location: Ningde, Fujian Province, China
- Equipment: Haitai SC Type 90 Ton Straddle Carrier
- Delivery Date: August 2025
- Industry: Lithium Battery Manufacturing
Six criteria defined the specification: explosion-proof and anti-static certification, dust-free and low-humidity operation, smooth low-speed travel to protect electrode materials, industrial digital integration with the factory MES system, multi-layer EHS safety redundancy, and full compliance documentation with long-term warranty coverage. Conventional straddle carriers designed for ports and steel yards can not operate safely in these conditions without extensive modifications.
Multiple suppliers were evaluated. Finally, Haitai Crane was selected as the single-source supplier for the complete electrical and mechanical system. Haitai Crane designed and customized a 90 ton straddle carrier crane meeting with all these requirements.
Client’s Six Core Requirements and Haitai’s 90 Ton Straddle Carrier Solution
1. Explosion-Proof and Anti-Static Electrical System
Battery material handling areas are classified as Zone 2 gas and Zone 21 dust hazardous locations. The explosion-proof motor, VFD drive, and PLC control cabinet carry Ex d e ib IIB T4 (gas) and Ex tD A21 IP65 (dust) certification. All electrical enclosures are sealed with double-gasketed stainless steel construction. Anti-static grounding is achieved through a dedicated copper mesh integrated into the chassis, with measured resistance below 10⁶ ohms per IEC 60079-14. Static dissipative tyres are fitted to prevent charge accumulation during travel.
2. Dust-Free, Low-Humidity, and Corrosion-Resistant Design
All hydraulic fittings use O-ring face seal (ORFS) connections to eliminate leakage. Electrical enclosures are IP65 rated with conformal-coated PCBs and desiccant breathers. The machine is designed to operate in environments with relative humidity below 40% without condensation risk. Stainless steel fasteners and coated structural components prevent corrosion from electrolyte vapour exposure. Particle emission testing by CATL confirmed compliance with ISO Class 8 (100,000) cleanroom standards at the point of use.
3. Smooth Low-Speed Precision Transport
Electrode material handling requires acceleration below 0.05 m/s² to prevent particle shedding and cell damage. The VFD-controlled drive system provides creep speed down to 3 km/h with jerk-limited acceleration profiles. Closed-loop speed feedback from the drive encoder maintains velocity within ±2% of setpoint regardless of load position or gradient. The operator can position loads within ±5 mm of target using the proportional joystick control, which is critical when transferring electrode rolls between process stations.
4. Industrial Digital Integration
The machine communicates with CATL’s MES via OPC UA and MQTT protocols over a dedicated industrial Wi-Fi network. Real-time data transmission covers 47 tags including load weight, battery temperature, drive current, travel distance, hydraulic pressure, and fault codes. The PLC control cabinet integrates with CATL’s production scheduling system for automated task assignment. Operational data is logged and stored for six months, supporting predictive maintenance analysis.
5. Multi-Layer EHS Safety Redundancy
Safety is layered across three independent systems. Laser zone scanners on both ends create a configurable warning and stop zone, adjustable between 1 and 6 metres. Dual mechanical limit switches on the hoist and travel provide hard-stop backup. The cabin-operator emergency stop and four remote E-stop push buttons on the chassis allow immediate shutdown from any position. All safety circuits are SIL 2 rated per IEC 62061, with self-diagnostic checks every 500 milliseconds.
6. Full Compliance Documentation and Long-Term Warranty
Haitai supplied a complete compliance dossier including EC Type Examination Certificate, IECEx certificate of conformity, ATEX documentation, CE Declaration of Conformity, and site-specific risk assessment per ISO 12100. The explosion-proof motor, VFD drive, and control system carry a 36-month warranty. Annual explosion-proof re-certification inspections are included for the first five years. Spare parts for the control system and drive train are stocked regionally.
Technical Specifications of HT Crane 90 Ton Straddle Carrier
| Parámetro | Especificación |
|---|---|
| Modelo | Haitai SC Type Straddle Carrier |
| Capacidad nominal | 90 ton |
| Altura de elevación | 6.5 m |
| Inside Span (Leg Clearance) | 4.5 m |
| Velocidad de desplazamiento (con carga) | 0-8 km/h (creep mode: 3 km/h) |
| Acceleration Control | 0.05 m/s² |
| Sistema de transmisión | Explosion-proof VFD-controlled AC motor |
| Engine / Power Source | Diesel generator set, 150 KW |
| Explosion-Proof Classification | Ex d e ib IIB T4 / Ex tD A21 IP65 |
| Electrical Integration | OPC UA + MQTT, 47 data tags |
| Sistema de seguridad | SIL 2, dual laser zone scanners, dual limit switches |
| Anti-Static Grounding | < 10⁶ Ω per IEC 60079-14 |
| Temperatura de funcionamiento | -10°C to +50°C |
| Garantía | 36 months (electrical system), annual inspection included |
| Certificaciones | EC Type Examination, IECEx, ATEX, CE, ISO 9001 |
Operational Performance of 90 Ton Straddle Carrier Since Delivery
Since commissioning in September 2025, the 90 ton straddle carrier has operated for over 3,600 hours across two production shifts per day. CATL’s maintenance team reported zero unplanned electrical downtime during this period. The integrated explosion-proof motor, VFD, and PLC control cabinet — supplied as a single unified system — eliminated the coordination issues typically seen when multiple vendors supply individual components. Commissioning was completed in seven days rather than the 14 to 21 days typical for multi-supplier electrical systems.
The anti-static system has maintained grounding resistance below the 10⁶ ohm threshold in all weekly checks. No dust or particle contamination incidents have been recorded at the cleanroom interface points. CATL’s production engineering team confirmed that the machine’s acceleration and positioning performance met or exceeded the original specification during the ten-month performance review in July 2026.
Why This 90 Ton Straddle Carrier Project Matters for Battery Industry Buyers?
This case demonstrates that heavy material handling equipment can meet the strictest battery industry requirements without sacrificing productivity. The key decision factor for CATL was the single-supplier electrical system — a motor, VFD, and control cabinet carrying unified explosion-proof certification, common anti-static grounding, and a single warranty interface. For battery manufacturers evaluating heavy handling equipment, this approach reduces procurement complexity, eliminates certification gaps, and shortens commissioning timelines.
The specifications and operating data from this project are directly transferable to similar applications in lithium battery production, electric vehicle assembly, and energy storage system manufacturing worldwide.
Related Case Studies of Haitai Crane’s Straddle Carriers
Haitai has epxorted several straddle carriers to different countries since 2006, including 60 ton straddlecarrier, 50 ton straddle carrier, and 40 ton straddle carrier. This 90-ton straddle carrier case adds a new record of customized heavy-tonnage straddle carrier. If intrested, please click to read the following case studies.
If you have factories, plants, or port terminals requiring heavy container lifting cranes, please contact crane solutions specialist, Simon, to discuss your custom straddle carrier crane.
Preguntas frecuentes
Q1: What explosion-proof rating does the CATL straddle carrier carry?
The machine is certified Ex d e ib IIB T4 for gas atmospheres (Zone 2) and Ex tD A21 IP65 for dust atmospheres (Zone 21). All electrical components — motor, VFD, control cabinet, junction boxes, and sensors — carry unified certification. This means every electrical point on the machine meets the same hazardous area standard, eliminating the certification gaps that can occur when components from different suppliers are assembled.
Q2: How is electrostatic discharge prevented during operation?
A dedicated copper grounding mesh is integrated into the chassis structure, with measured resistance below 10⁶ ohms per IEC 60079-14. Static dissipative solid rubber tyres prevent charge accumulation during travel. All metal parts are bonded to the grounding system. The operator cabin includes anti-static flooring and ESD-safe seating. Grounding continuity is verified weekly as part of CATL’s preventive maintenance schedule.
Q3: Can this straddle carrier operate in a cleanroom environment?
Yes. All hydraulic fittings use O-ring face seal connections to eliminate oil leakage risk. Electrical enclosures are IP65 rated with conformal-coated PCBs and desiccant breathers. The machine does not generate metallic or rubber particulate during normal operation. CATL’s particle emission testing confirmed compliance with ISO Class 8 (100,000) cleanroom standards at the point of use. Additional sealing upgrades are available for ISO Class 7 environments if required.
Q4: What digital integration protocols does the machine support?
The machine communicates via OPC UA and MQTT over a dedicated industrial Wi-Fi network. 47 real-time data tags cover load weight, battery temperature, drive current, travel distance, hydraulic pressure, fault codes, and maintenance intervals. The PLC control cabinet integrates with the factory MES for automated task assignment and production scheduling. All operational data is logged and stored for six months. Custom tag mapping is available for integration with specific MES or SCADA platforms.
Q5: What after-sales support is provided for the explosion-proof system?
The explosion-proof motor, VFD drive, and control system carry a 36-month warranty. Annual explosion-proof re-certification inspections are included for the first five years. Spare parts for the control system and drive train are stocked regionally. Remote technical support is available 24/7 via WhatsApp and email. On-site service can be dispatched within 48 hours to Fujian province.
Q6: Can you provide customized technical drawings for the 90 ton straddle carrier?
Yes, we provide custom general layout and foundation drawings upon formal inquiries to protect commercial confidentiality. Please trust our professional team and technique.
Q7: What classification society certifications do your port straddle carrier cranes support?
Our straddle carrier cranes are manufactured to meet international standards and can be certified by ABS, BV, DNV, and CCS according to your project requirements.
