Capacity per hoist, hoist count, track layout and duty class — the four decisions that decide whether a workstation crane system covers your line smoothly or turns into a costly web of track nobody planned. Written for assembly lines, packing cells and fabrication shops that want multi-station lifting without buying one crane per bench.
A combination crane — also called a workstation crane — is a modular track network that lets two or more hoists travel over a production area, sharing track instead of each station owning its own crane. It is the right tool when you have multiple workstations under 2 tons per hoist and the loads move along a flow path, not in one fixed spot. Sizing it is different from sizing a single crane: you decide capacity per hoist, then how many hoists the line really needs, then the track geometry, then the duty class. This guide covers the typical ranges (0.125-2 t per hoist, one hoist per 2-3 stations, straight/curved/switchable track, A3-A5 duty classes) and closes with a specification template that gets you comparable quotes.
Capacity per hoist is where combination crane projects go wrong, and usually in the same direction: buyers size every hoist for the heaviest item in the building, then pay for that rating on every station. A combination crane shares hoists across the network, so the rating that matters is the heaviest regular load at the busiest station — not the rare oversized piece that a forklift or a gantry crane can handle once a month.
Start with that heaviest single item, then apply the standard margin: size to at least 125% of the load to cover the load test requirement and lifting fixtures. A 0.5-ton hoist routinely lifting 450 kg motors is running near its test limit, and on a shared line that is a chain and brake wear problem waiting to happen.
| Capacity per hoist | Typical regular loads | Where it fits |
|---|---|---|
| 0.125 - 0.25 t | Small parts, tooling, electronics | Light assembly cells, packing, labs |
| 0.5 t | Pumps, motors, packaged goods to 0.4 t | Assembly lines, warehouse picking, packing cells |
| 1 t | Machine components, engines, packed crates | Medium fabrication, sub-assembly, loading bays |
| 2 t | Heavy machine parts, molds, loaded skids | Heavy workstation work at the top of the range |
Above 2 tons per hoist, stop and question the combination route. The enclosed track profile and support steel grow faster than the benefit, and a single girder overhead crane with its own runway usually becomes the cheaper answer. Combination cranes win in the 0.125-2 ton zone — that is their home turf, and that is where the shared-track economics work.
This is the question that separates a good combination crane layout from an expensive one, and it is the one most buyers never ask the supplier. The whole point of the system is that hoists travel over switches and share track — so you do not need one hoist per station. The rule we use in practice is one hoist for every 2-3 workstations.
The deciding factor is simultaneous lifting. Walk the line during a normal shift and note which stations lift at the same moment. If two stations never lift at the same time, one hoist covers both. If three stations feed a machine in sequence, one hoist on a straight line handles the whole flow. If every station runs a full cycle simultaneously, you need closer to one hoist per station — and at that point, honestly, the combination crane may not be the right system at all.
| Line pattern | Stations | Hoists needed | Logic |
|---|---|---|---|
| Sequential assembly, one flow direction | 3 | 1 - 2 | Stations rarely lift together |
| Parallel cells, independent cycles | 4 | 2 - 3 | Two cells may lift at once |
| Typical 5-station line | 5 | 3 | Standard design point |
| Full simultaneous cycles | 4 | 4 | Reconsider the system type |
Each extra hoist adds USD 1,200-6,000 to the equipment price depending on capacity, so cutting one hoist from a 5-station line is not a small saving. On the other side, under-specifying hoists creates queuing at the busiest stations and operators end up waiting for the trolley — which quietly costs more in lost production than the hoist would have. Map the simultaneous-lift pattern first; the hoist count follows from it. Our combination crane assembly line guide covers multi-station layout planning in more depth.
Track layout is where the combination crane earns its name, and also where budgets balloon if nobody plans it. The system is built from straight sections, curves, switches and turntables, and the layout should mirror the material flow — not the building grid. Draw the line your product actually travels, then place track on top of that line.
| Component | Cost (2026) | What it does |
|---|---|---|
| Straight track | USD 400 - 800 per 6 m | The cheapest way to cover a line of stations |
| Curve | USD 200 - 500 each | Turns the line around columns and obstacles |
| Switch | USD 600 - 1,200 each | Lets one hoist serve two parallel lines or a bypass |
| Turntable | USD 1,000 - 2,500 each | Changes travel direction at right angles |
Start simple. A straight run over the busiest stations covers most assembly and packing lines, and it is the cheapest layout per meter. Add a switch only where a second line or a bypass is genuinely used — every switch is a moving part, a wear point and a maintenance item on a system that is otherwise nearly maintenance-free. Curves let you route around columns without raising the roof, which is often cheaper than relocating the line. Turntables earn their cost only where the flow genuinely turns 90 degrees; if the building can be laid out to avoid the turn, avoid it.
A practical sizing note from our installs: total installed cost runs 1.2 to 1.5 times the equipment price once track support steel, hangers and electrification are added. Complex layouts with many switches push that ratio toward the top, because each switch needs its own support and control wiring. If you are comparing a straight 3-station line against a switchable 5-station network, compare installed totals, not just the track price. Our combination crane cost & TCO guide breaks down track, hoist and installation costs in detail.
Duty class tells you how many hours a day the crane can work and how often it can lift near its rated load. Combination cranes are built for light and medium service, which matches their natural home at workstations and assembly cells.
| Duty class | Working hours / day | Typical applications |
|---|---|---|
| A3 | A few hours, occasional lifts | Maintenance bays, tool rooms, lab handling |
| A4 | 4 - 8 hours | Assembly lines, packing cells, warehouse picking |
| A5 | 8 - 16 hours | Busy production cells, continuous light handling |
On a combination crane, the hoist is the component that wears first — the track itself is enclosed steel designed for 20-30 years indoors. So match the duty class to the hoist duty cycle, not just to the line hours. A packing cell working two shifts at A5 needs a hoist rated for that continuous cycle; putting an A3 hoist on it means replacing the load chain every 2-3 years instead of 5. If a station genuinely needs more than 16 hours a day of continuous work, an overhead crane is the honest answer — pushing a light-duty workstation hoist past its class shortens chain and brake life noticeably, and the cost of downtime on a busy line dwarfs the price difference.
Chain hoists dominate combination crane systems, and for good reason: the capacity range tops out at 2 tons, lift heights stay at 2-8 m, and chain is cheaper, lighter and easier to service at these sizes. Wire rope hoists appear at the top of the range where faster lifting and longer hook travel justify the extra cost.
| Factor | Chain hoist | Wire rope hoist |
|---|---|---|
| Typical capacity | 0.125 - 2 t | 1 - 2 t (top of range) |
| Lift height | Up to ~6 m standard | Up to 8 m and beyond |
| Lifting speed | Slower, single speed typical | Faster, two-speed common |
| Price | Lower, typically 15-25% less | Higher |
For assembly and packing lines in the 0.125-1 ton range, a chain hoist is the sensible pick — cheaper, compact, and plenty for the job. For 2-ton stations, longer lifts or faster cycles, a wire rope hoist earns its extra cost. On a shared track, keep the hoists uniform: mixing chain and wire rope hoists on one network complicates spares, trolley interfaces and operator training for little benefit.
Combination crane track hangs from one of two supports: the building roof structure or a free-standing column framework. This is the structural decision most buyers skip until the quote stage, and it is the one that changes both price and installation timeline.
| Factor | Ceiling-suspended | Free-standing |
|---|---|---|
| Building dependence | Roof/steel structure must take track loads | Independent; own columns and foundations |
| Cost premium | Base price | + USD 2,000 - 6,000 support framework |
| Floor impact | Clear floor below track | Columns take floor space |
| Best for | Buildings with verified steel roof structure | Weak roofs, retrofits, rented buildings |
Ceiling-suspended is the economical default when the roof structure can take the loads — and it is the first thing to verify, not the last. Send the supplier the roof framing plan, column spacing and truss details before quoting. If the building is old, has lightweight roof panels, or the track spans must cross a wide open bay, free-standing columns add USD 2,000-6,000 but remove all doubt about the structure. In rented buildings, free-standing is often the only option that does not require the landlord's sign-off on roof penetrations. When the roof truly cannot carry the loads and floor space is available, a gantry crane running on floor rails is worth comparing before you commit to a column framework.
Prices below are 2026 FOB estimates for CE-certified Chinese combination crane systems with hoists, controls and electrified busbar, excluding track support steel, freight and installation. Expect total installed cost to run roughly 1.2 to 1.5 times the equipment price — the support steel and hangers are the part buyers underestimate most.
| System configuration | Capacity / hoist | Track & hoists | Price range (FOB) |
|---|---|---|---|
| Single station, ceiling-suspended | 0.25 t | 6 m / 1 hoist | USD 1,200 - 1,800 |
| Single station, ceiling-suspended | 0.5 t | 6 m / 1 hoist | USD 1,800 - 2,800 |
| 2-station with switch | 0.5 t | 12 m / 1 hoist + 1 switch | USD 2,800 - 4,200 |
| 3-station with switches | 1 t | 18 m / 2 hoists + 2 switches + 2 curves | USD 5,000 - 8,000 |
| 5-station line | 1 t | 60 m / 3 hoists + 4 curves + 3 switches | USD 14,000 - 21,000 |
| 5-station line (heavy) | 2 t | 60 m / 3 hoists + 4 curves + 3 switches + turntable | USD 18,000 - 24,000 |
| 8-station complex line | 1 t | 120 m / 4 hoists + 8 curves + 5 switches + 2 turntables | USD 28,000 - 40,000 |
Two notes on comparing quotes. First, confirm every supplier quotes the same hoist count and track complexity — a 3-station line with 2 hoists and 2 switches costs less than the same line with 3 hoists and 4 switches, and comparing them as if they were the same system misleads you. Second, ask what the price includes: some quotes cover track, hoists and busbar but exclude support steel and hangers, which are a real cost on complex layouts. Our combination crane cost & 10-year TCO guide breaks down installation, maintenance and energy costs in detail — including the finding that a 5-station combination crane saves roughly 30-40% in 10-year TCO versus five separate jib cranes.
A vague enquiry gets a vague quote. A complete specification gets comparable quotes — and saves you from paying for a change order later. Send every supplier the same ten items:
If you plan to extend the line later — add stations, a bypass, or a second parallel line — say so in the enquiry. The supplier can size the track profile and electrification for future expansion, which is far cheaper than adding switches to an undersized network later.
Start from the heaviest regular single load at the busiest station, multiply by at least 1.25 to cover the load test margin, and round up to a standard capacity. 0.125-0.25 tons covers small parts and tooling, 0.5 ton pumps and motors, 1 ton machine components, and 2 tons the heavy end of workstation work. Above 2 tons per hoist, a light overhead crane is usually the better choice.
One hoist for every 2-3 workstations is the practical rule. A 5-station line typically needs 3 hoists, not 5. The deciding factor is simultaneous lifting: if two stations never lift at the same moment, they can share one hoist. If every station lifts at once, you need closer to one hoist per station, and the combination crane may not be the right system.
Mirror the material flow, not the building grid. Straight runs are cheapest (USD 400-800 per 6 m), curves cost USD 200-500 each, switches USD 600-1,200 each, and turntables USD 1,000-2,500 each. Start with a straight line over the busiest stations and add switches only where a second line or bypass is genuinely used — every switch is a moving part and a maintenance point.
A3 covers occasional lifting a few hours a day — maintenance and tool rooms. A4 covers 4-8 hours — assembly lines, packing cells, warehouse picking. A5 covers 8-16 hours — busy production cells. Match the duty class to the hoist duty cycle, since the hoist wears first on a combination crane. More than 16 hours a day calls for an overhead crane.
Equipment prices run USD 1,200-40,000 FOB depending on station count, capacity and track complexity. A single 0.25-ton station is about USD 1,200-1,800; a 3-station 1-ton system about USD 5,000-8,000; a 5-station 1-ton line about USD 14,000-21,000; a complex 8-station line USD 28,000-40,000. Installed totals run 1.2 to 1.5 times the equipment price once support steel and electrification are added.
Send us your line layout, heaviest loads and operating hours — our engineering team will confirm the right capacity, hoist count, track geometry and duty class before you commit to anything. Quotes include a full specification sheet you can compare with other suppliers.
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