20 Ton Transfer Cart Delivered to Singapore: Rail Installation Solution for Existing Concrete Floors

ZOKE CRANE customized and delivered a 20-ton KPJ Cable Reel Transfer Cart for an engineering contractor in Singapore. The transfer cart features a 6 × 2.3 m platform, a 30 m travel distance, and a 440V/3PH power supply.

The customer's concrete floor had already been completed before deciding to adopt a rail-mounted solution. To avoid damaging the existing floor, we used a "steel plate + chemical anchor bolt" installation method to fix the square rails, minimizing site modification. The entire process, from inquiry to order confirmation, took less than one month.

Design Challenges of the Cable Reel Transfer Cart on an Existing Concrete Floor

Based on the customer's workshop conditions and customization requirements, this project involved several unique challenges that became the key value of the final solution.

No Embedded Rail Foundation and No Major Civil Construction Allowed

The workshop floor was fully completed concrete without embedded rail plates or foundations. Traditional rail installation methods involving floor cutting, trenching, and concrete pouring would damage the existing workshop floor, extend the construction period, and significantly increase civil engineering costs. This did not meet the customer's requirement for a low-cost retrofit. In addition, the rail gauge was fixed at 1.6 m and required precise installation.

Non-Standard Industrial Voltage Requiring a Fully Customized Electrical System

The customer's power supply did not match common industrial voltage standards. Many suppliers only provide standard voltage equipment and lack the capability to customize complete electrical systems, which can lead to startup failures and frequent electrical problems.

At the same time, the workshop operates continuously under high-frequency conditions and requires excellent overload resistance, durability, and reliability, making standard low-end electrical components unacceptable.

From Selection Challenges to Project Completion: How We Built a Custom KPJ Cable Reel Transfer Cart

To address the customer's requirements, our engineering team developed a low-cost, low-modification, and highly adaptable solution. The main advantages focused on the rail installation process and the customized electrical system.

Steel Plate and Chemical Anchor Rail Installation Reduces Modification Costs

To avoid large-scale civil construction and control overall project costs, we adopted a non-embedded rail installation solution using steel base plates and chemical anchor bolts.

Thick steel plates were fixed directly onto the existing concrete floor using high-strength chemical anchors. After accurately adjusting the level and the 1.6 m rail gauge, the rails were welded onto the steel base plates.

This solution offers several advantages:

• No floor cutting or concrete pouring, with minimal impact on the existing workshop floor.
• Significantly lower civil construction costs and excellent overall cost performance.
• Strong anchoring force, excellent vibration resistance, and long-term reliability.
• High rail installation accuracy and stable structure without the risk of rail deviation.

Fully Customized for Non-Standard Voltage, Ready for Immediate Use

Unlike suppliers that only support standard voltages, ZOKE CRANE has complete electrical customization capabilities. For this project, the motors, control systems, and power supply systems were all customized to match the local voltage requirements.

Complete electrical testing and commissioning were finished before shipment, allowing the customer to put the equipment into operation immediately without any modifications or component replacement.

Full Schneider Electrical Configuration for Greater Reliability

To meet the customer's high reliability requirements, the entire electrical system of the transfer cart was equipped with imported Schneider components, including switches, contactors, relays, and protection modules.

This premium configuration is ideal for continuous heavy-duty operation, offering lower failure rates, stronger overload resistance, smoother operation, and a longer service life while reducing maintenance costs.

Expedited Production and Direct Ocean Shipping

After receiving the customer's urgent delivery request, we activated a priority production schedule, allocating manufacturing resources to complete assembly, testing, and anti-rust packaging in the shortest possible time.

At the same time, dedicated international shipping channels were arranged, keeping the total sea transportation time within 12-15 days. The customer only needed to complete simple assembly and power connection after receiving the equipment, significantly shortening the project implementation cycle.

Project Delivery Results

The main technical specifications are as follows:

After expedited manufacturing and final inspection, the equipment was shipped immediately. With a fast sea transit time of only 12-15 days, the customer quickly received a ready-to-use material handling solution.

The transfer cart adopted a mature and standardized structure. The customer only needed to complete simple on-site installation before putting the equipment into operation.

Project Summary

This Singapore Cable Reel Transfer Cart project successfully delivered a highly cost-effective and customized solution through three major advantages:

Low-modification rail installation using steel plates and chemical anchors.

Complete Schneider electrical customization for non-standard voltage requirements.

Fast-track production and end-to-end delivery management.

From rapid order confirmation and short delivery time to a fully customized solution tailored to the workshop conditions, this project demonstrates ZOKE CRANE's strong capabilities in non-standard rail transfer equipment, low-cost retrofit solutions, and customized electrical systems.