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Taisun
Taisun
Taisun
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Taisun lifts the 17,100-ton deck box of the Scarabeo 9 semi-submersible.

Taisun (Chinese: 泰山; pinyin: tàishān; Taishan) is a gantry crane with a safe working load of 20,000 metric tons (22,046 short tons).[1] Taisun was designed by DHHI (Dalian Huarui Heavy Industry)[2] and built for the installation of very large modules in semi submersibles and FPSO projects. It is located at Yantai Raffles Shipyard in Yantai, Shandong Province, China. The gantry crane holds the record for the heaviest weight lifted by a crane.[3]

The amount of wire required to operate Taisun is nearly 50,000 meters or just over 31 miles, allowing it to lift a maximum of 80 meters.

Taisun seen lifting the 14,000-ton deck box of the COSL Pioneer drilling semi-submersible.

Concept

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Taisun was built to install very large (up to 20,000 tons) integrated modules on top of a vessel's hull. Traditionally, offshore vessels such as drilling semi submersibles or FPSOs were built from the ground up in modules of 1000 to 2000 tons, which meant that much installation, hook up and commissioning work was left to be done on board where access is limited and efficiency is decreased.

Taisun facilitates simultaneous construction of the lower and upper parts of the vessel which allows for a shorter overall project schedule, manpower improvements of up to two million man-hours while safety and quality levels are improved.[4]

Taisun with the now-complete SS Amazonia drilling semi-submersible.

Lift Record

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The Guinness World Records state that Taisun holds the world record for "heaviest weight lifted by crane", set on April 18, 2008 at 20,133 metric tonnes (44,385,667.25 lb) by lifting a barge, ballasted with water.[3] However, it was surpassed by the Honghai Crane when the new crane was completed in 2014, with a lift capacity at 22,000 tonnes.[5]

Taisun setting the heavy lift world record at 20,133 metric tons

Particulars

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Safe Working Load 20,133 metric tons
Height 133 meters
Span 120 meters
Maximum lift height 80 meters
Dry dock length 380 meters
Wire rope length 50,000 meters

References

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Taisun

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from Grokipedia
Taisun is a massive located at the in , Province, , recognized as the world's most powerful gantry crane due to its unprecedented safe working load of 20,000 metric tons. Designed and constructed by Dalian Heavy Industry (DHHI), a leading Chinese engineering firm, Taisun measures 133 meters in height and spans 120 meters across, enabling it to handle enormous modules for offshore structures such as semi-submersibles and (FPSO) vessels. Commissioned in 2008, Taisun holds the Guinness World Record for the heaviest weight ever lifted by a crane, achieving a lift of 20,133 metric tons on April 18 of that year using a water-ballasted . It has also performed other record-setting lifts, including 17,100 metric tons for the Scarabeo 9 topsides and 14,000 metric tons for the COSL Pioneer deck box, demonstrating its critical role in accelerating projects by reducing timelines and manpower requirements by up to two million hours per operation. In recognition of its engineering excellence, Taisun received the Woelfel Best Achievement Award at the Offshore Technology Conference (OTC) in 2008. The crane's advanced design incorporates 50,000 meters of and allows lifts up to 80 meters high, prioritizing safety, environmental compliance, and precision in heavy-lift operations for the global maritime and industries. By enabling the integrated assembly of large-scale components onshore, Taisun has revolutionized and offshore platform , minimizing risks associated with traditional sea-based lifts.

Development and Construction

Design Origins

The Taisun crane originated from the need to address significant challenges in the shipbuilding industry during the early 2000s, particularly the difficulties in assembling massive offshore modules for semi-submersibles and FPSO (Floating Production Storage and Offloading) vessels. Traditional construction methods relied on multiple smaller cranes and extensive on-site welding, leading to prolonged timelines, high labor demands, and increased safety risks. Dalian Huarui Heavy Industry (DHHI), a leading Chinese heavy machinery manufacturer, initiated the conceptual development to create a single, ultra-high-capacity gantry crane capable of handling entire pre-fabricated modules, thereby revolutionizing the integration process at shipyards. DHHI's design was tailored specifically for the Yantai Raffles Shipyard in Province, , where the growing demand for large-scale offshore structures necessitated more efficient assembly techniques. By enabling the lifting and precise placement of complete sections weighing thousands of tons, Taisun was engineered to reduce overall project assembly time by up to 2 million man-hours per vessel and enhance worker safety through minimized on-site welding and reduced exposure to hazardous lifting operations. This approach allowed for of a vessel's lower hull and upper modules. Key engineering challenges in the design phase included ensuring structural integrity under extreme loads while maintaining operational precision over vast spans, with a focus on a robust gantry framework to cover the shipyard's extensive . Innovations such as the world's first fixed dual-beam gantry configuration provided the necessary stability and reach for these operations, supporting a safe working load of 20,000 metric tons. DHHI incorporated advanced self-developed control systems to achieve fine-tuned movements, further mitigating risks in handling oversized components.

Construction Process

The construction of the Taisun was managed by Dalian Heavy Industry Group (DHHI) at the Yantai Raffles Shipyard in , Province, . The project commenced in early 2007, with testing beginning in November of that year, and was completed after approximately one year of intensive building efforts, with the crane christened on April 23, 2008, prior to its operational handover. Designed to support lifts of up to 20,000 metric tons, the involved significant logistical coordination to erect the massive frame and integrate control systems for safe heavy-lift operations. Key milestones included the completion of major assembly phases in early 2008, enabling subsequent testing before the crane entered service at the .

Technical Specifications

Structural Features

Taisun features a fixed dual-beam gantry design, consisting of two parallel legs that support a robust crossbeam, enabling it to and operate over large workspaces. This architectural configuration allows for the precise positioning and lifting of oversized loads within its operational envelope. The crane's legs are engineered to provide stability across the full span, facilitating integration with processes. The overall of Taisun measures 133 meters, comparable to a 40-story building, while its span extends 120 meters—wider than a standard soccer field. These dimensions position the crane above a 380-meter-long , optimized for the assembly and integration of ship modules such as offshore platform sections. The maximum lifting reaches 80 meters above ground level, providing ample clearance for maneuvering heavy components during . This structural scale supports Taisun's role in enabling single-lift operations for massive modules, as explored in its major projects.

Lifting Mechanisms

Taisun's lifting mechanisms are engineered to achieve unprecedented load capacities through a combination of robust hoisting systems and advanced power delivery. The crane's safe working load stands at 20,000 metric tons, enabling it to handle massive modules in and . This capacity is supported by a total length of 50,000 meters distributed across multiple hoists, providing the necessary reach and tension distribution for stable lifts up to 80 meters high. The core of the lifting system utilizes an advanced drive configuration integrating electrical and hydraulic components for and control in high-load scenarios. Wire ropes are arranged to distribute load evenly and minimize stress concentrations. Control systems play a critical role in synchronizing the multiple hoists, preventing imbalances during operations. These include anti-sway that adjusts motor speeds in real time to counteract load oscillations, along with load monitoring sensors that track tension and for operational safety. The system supports both single and lifts of up to 20,000 tons, with an adjustable speed of up to 0.24 meters per minute at full load to balance power and stability. Key Specifications of Lifting Mechanisms
ComponentDetails
Safe Working Load metric tons
Total Wire Rope Length50,000 meters across multiple hoists
Drive SystemAdvanced electric-hydraulic configuration
Control FeaturesSynchronized lifting, anti-sway technology, load sensors
Maximum Speed0.24 m/min at full load
Lift TypesSingle or tandem up to tons

Operational History

Commissioning and Early Use

Taisun was commissioned in April 2008 following initial load tests at the Yantai Raffles Shipyard in Yantai, Shandong Province, China, where it has remained operational with an initial focus on installing modules for offshore oil and gas projects. The commissioning process included progressive load tests, with early efforts reaching up to approximately 10,000 tons using ballast water configurations to verify structural integrity. Full certification for operational use was granted by mid-2008 through oversight by relevant authorities, including the American Bureau of Shipping, enabling safe deployment for heavy-lift applications. The crane's early operations encountered challenges in calibrating control systems, where sensor data from maintenance lifts revealed discrepancies in load measurements during lifting and lowering phases, leading to abnormal height variations of about 30 cm due to inaccuracies in computer models or unaccounted forces. Integration with shipyard workflows also required refinements to the systems and encoder-based monitoring to ensure even load distribution across hook groups, transitioning from a multi-stage manual process to more unified deterministic controls. Taisun achieved its first commercial use in late November 2008, when it lifted the 14,000-tonne deckbox of the COSL Pioneer for Limited, demonstrating its capacity to assemble large modules onshore and thereby reducing reliance on traditional float-out methods in challenging sea conditions. This 20,000-tonne safe working load enabled precise mating of hull sections and topsides, streamlining assembly for offshore platforms during its startup phase from 2008 to 2010.

Major Projects

One of Taisun's inaugural major projects was the installation of the 14,000-ton deck box for the COSL Pioneer in November 2008 at the Raffles Shipyard. This lift marked the crane's first commercial operation, where the deck box was hoisted onto the rig's lower hull, enabling efficient of platforms. The operation, conducted for COSL Drilling Europe AS, demonstrated Taisun's capability for heavy- mating in , reducing assembly time compared to traditional methods. In December 2009, Taisun executed another significant lift by raising the 17,100-ton topsides module for the Scarabeo 9 semi-submersible drilling rig, built for . This operation involved mating the deck box onto the rig's pontoons, setting a benchmark for ultra-deepwater rig construction with a variable load displacement of over 50,000 tons. The project highlighted Taisun's role in supporting high-specification offshore assets capable of operating in water depths up to 3,657 . Beyond these early milestones, Taisun has facilitated the assembly of (FPSO) units and jack-up rigs, including modules for contracts involving and through 2015. For instance, in June 2015, it mated the 18,727-ton upper deck with the 19,277-ton lower hull of the Frigstad Deepwater Rig Alfa, a seventh-generation , as part of Saipem-related developments. By that year, Taisun had completed at least 11 such major matings for deepwater semisubmersibles, primarily in the offshore oil and gas sector. Taisun's operations have extended to over a dozen heavy lifts by the mid-2010s, with continued use in offshore construction.

Records and Significance

World Records

Taisun holds the Guinness World Record for the heaviest weight ever lifted by a crane, achieving a lift of 20,133 metric tons using a test load on April 18, 2008, at the Yantai Raffles Shipyard in China. This record remains unbroken as of 2025, with no subsequent lifts surpassing it in verified documentation. In addition to its primary record, Taisun maintains the top three heaviest verified lifts by any crane: 20,133 metric tons in 2008, followed by 17,100 metric tons during the assembly of the Scarabeo 9 semi-submersible in 2009, and 14,000 metric tons for the COSL Pioneer in 2009. These achievements underscore Taisun's dominance in heavy-lift operations within and . Compared to other major cranes, Taisun's actual lift records exceed those of competitors, including the , which boasts a theoretical capacity of 22,000 metric tons but has no documented lifts surpassing Taisun's verified feats as of 2025. It also significantly outperforms fixed gantry cranes like the in , limited to a maximum capacity of 1,500 metric tons. No updates or surpassals to these records have been reported by 2025, affirming Taisun's ongoing status in heavy-lift engineering.

Industry Impact

Taisun has revolutionized heavy module integration in the and offshore industries by enabling the land-based assembly of large structural components, such as those for semi-submersibles and (FPSO) units, thereby minimizing the hazards and complexities of traditional sea-based lifting operations. This approach has substantially lowered construction costs and timelines through significant labor efficiencies, with projections indicating savings of over 2 million man-hours per by streamlining handling, lifting, and integration processes on solid ground. Taisun's capabilities have bolstered China's position as a leading player in global , facilitating the efficient production of energy infrastructure components and supporting the sector's expansion amid rising demand for oil and gas platforms. In terms of safety, the crane has markedly enhanced worker protections by shifting assembly activities from precarious offshore environments—exposed to heights, adverse weather, and water hazards—to controlled onshore facilities, thereby reducing accident risks and improving overall project quality. Its pioneering design has influenced the development of later heavy-lift systems, including the Honghai , by setting new benchmarks for capacity and modular construction techniques in the industry. As of 2025, Taisun continues to operate at the Raffles Shipyard without significant upgrades, maintaining its role in diverse applications.

References

  1. https://www.guinnessworldrecords.com/world-records/heaviest-weight-lifted-by-a-crane
  2. https://en.clickpetroleoegas.com.br/o-guindaste-mais-potente-do-mundo-capaz-de-levantar-20-133-toneladas-de-uma-so-vez-e-que-monta-secoes-inteiras-de-plataformas-de-petroleo-btl96/
  3. https://www.marineinsight.com/know-more/6-largest-gantry-cranes-in-the-world/
  4. https://scarlet-tech.com/worlds-biggest-strongest-crane/
  5. https://emersoncranes.com/what-is-the-worlds-most-powerful-crane/
  6. https://gcaptain.com/building-the-worlds-largest-crane/
  7. https://www.kongsberg.com/maritime/news-and-events/our-stories/great-lift-great-leap---yantai-raffles/
  8. https://gcaptain.com/first-lift-worlds-largest-crane-in-action/
  9. https://www.kscranegroup.com/posts/largest-gantry-crane-in-the-world/
  10. https://vertikal.net/en/news/story/5770/world039s-largest-crane-is-christened
  11. https://www.hoistmagazine.com/analysis/tests-begin-on-giant-gantry/
  12. https://gruasytransportes.wordpress.com/wp-content/uploads/2014/11/taisunbrochure200907english-090714191733-phpapp01.pdf
  13. https://www.pacificindustrial.com/blog/news/news/taisun-the-worlds-strongest-crane
  14. https://www.scribd.com/document/95456356/General-Considerations
  15. http://www.worldrecordacademy.com/technology/largest_gantry_crane_Taisun_sets_world_record_80241.htm
  16. https://www.shipandoffshore.net/news/shipbuilding/detail/news/yrs-celebrates-taisuns-first-commercial-lift.html
  17. https://www.upstreamonline.com/online/yantai-raffles-rolls-out-monster-crane/1-1-1082616
  18. https://www.cranestodaymagazine.com/news/gantry-crane-lifts-17-000t/
  19. https://www.youtube.com/watch?v=p4GOPvYuGUo
  20. https://www.cimc-raffles.com/en/show-29-568-1.html
  21. https://en.clickpetroleoegas.com.br/os-maiores-guindastes-do-mundo-a-engenharia-por-tras-e-como-seu-poder-na-industria-desafia-o-conhecimento-comum-ctl01/
  22. https://www.cranegrabbucket.com/news/the-world-5-largest-marine-cranes-and-their-remarkable-capabilities-221471.html
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