Crane Selection and Application

Introduction

This presentation was developed as a teaching aid with the support of the American Institute of Steel Construction. It is primarily intended to be used by Construction Management programs to supplement classes in Construction Methods and Construction Equipment but also provides examples applicable to Estimating, Soils, Statics and Structures. The presentation materials would also be applicable in Architecture and Civil Engineering programs. You will need to enable Macros in PowerPoint to use these functions. Because viruses are sometimes transmitted through Macros, the default security setting for PowerPoint is usually High. This must be changed to Medium before opening the presentation. The security setting can be changed by first closing the presentation. In PowerPoint select Tools|Macro|Security Select Medium. Reopen this presentation and select Enable Macros when prompted by the Security Warning. See the Slide Notes for additional information
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This presentation contains several interactive Macros.

Crane Selection and Application

Crane Types Crane Selection Crane Capability Evaluation Crane Use Optimization Estimate of Crane Costs Jobsite Methods and Management

Load Macro Data

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Crane Types

Rough Terrain

Truck Mounted

All Terrain

Tower
See also [1], 53-66, 78-81

Crawler Lattice

Types of Cranes

Rough Terrain
Designed for unimproved work sites Roadable for short distances Four steering modes Pick and carry capability Three position outriggers
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Truck Mounted

Can be driven at highway speeds Limited off-road capability Can do multiple jobs in one day Hydraulic booms allow fast setup but the weight (compared to lattice) reduces lifting capability

All Terrain
Combines features of Rough Terrain and Truck Mounted cranes Off-road capable All-wheel steering Highway speeds

Crawler Lattice
High-capacity, longreach lifts Pick and carry operations Multiple attachments provide great flexibility in boom configuration

Tower
Used when space is at a premium Up and over reach Moving counterweight balances load Fixed foundation or Crawler w/attachment

Crane Selection
Selection criteria Crane data sheet examples
Rough Terrain - Grove RT700E Crawler Lattice - Manitowoc Model 777

Manufacturer web sites

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Crane Selection Criteria

Available space Working range Load charts Crane availability Number of lifts

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Available Space
Can crane fit on jobsite? Can crane maneuver as required on jobsite? Can the boom configuration reach all required placement positions? Can boom avoid existing obstacles while performing required movements?
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INFO

Available Space
Clicking on the category button will briefly describe the crane's capabilities.

Tower

Hydraulic

Crawler

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Working Range
Working range diagram shows the cranes reach Load capacity will be significantly reduced at long radii Diagram also shows range of boom angles and attachment geometry
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INFO LOAD

Load Charts

NOTES: 4. Capacities appearing above the bold line are based on structural strength and tipping should not be relied upon as a capacity limitation.

Load charts provide the authoritative load capacity for all crane configurations at all ranges Load Chart NOTES must be followed 4. Weight of the block, rigging equipment and cable below the boom must be subtracted from load capacity to determine actual payload

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Crane Availability
As with most types of construction equipment, the theoretically optimal crane for the job based on capability may not be readily available, or a more capable crane that is owned by the steel erector may be more economical Availability will always be an important factor in crane selection
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Number of Lifts
Fixed costs for crane mobilization will be more significant for smaller jobs requiring fewer days on site A crane that can perform all lifts from a small number of positions (or a single position) on the job site may be highly desirable even if mobilization and operating cost are higher
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Crane Data Sheets

Specifications Dimensions and weights Working range Load charts Notes to load charts

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Rough Terrain Hydraulic Crane

Grove RT700E
50-60 ton capacity at 12 ft radius 36 ft 110 ft, 4 section, full power boom 33 ft 56 ft bifold lattice swingaway extension 20 ft or 40 ft extension inserts 12,150 lbs counterweight pinned to superstructure

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Critical RT700E Dimensions

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Critical RT700E Dimensions

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RT700E Weights

Crane weight is critical when hauling The counterweight may have to be removed and transported on a separate vehicle
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INFO

Selected RT700E Specifications

Boom Information
Clicking the buttons showing standard crane symbols will provide the information from the specification describing that characterstic of the RT700 crane.

Fixed

Counterweight

Bi-Fold

Steering

Insert s

Gradeability
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RT700E Working Range

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LOAD

RT700E Capacity Calculator

Boom Cntrwgt Outriggers

110 ft.
Rotation

12,150 lbs. 50% Insert

Spread 17 ft. 4 in.

Select a crane configuration from the options provided. If that configuration is allowed, the load chart will be displayed on the following slide.
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Fixed Swingaway

360 deg

20 ft.

Length 56 ft.

Offset 25

LOAD

RT700E Load Chart (pounds)

33 ft. LENGTH 56 ft. LENGTH Radius 0 deg 25 deg 45 deg 0 deg 25 deg 45 deg in OFFSET OFFSET OFFSET OFFSET OFFSET OFFSET Feet #4064 #4065 #4066 #4084 #4085 #4086

35 40 45 50 55 60 65 70

9,360 (78) 9,360 (77) 8,480 (75.5) 7,680 (73.5) 6,990 (71.5) 6,190 (70) 5,890 (68) 5,390 (66)

7,480 (78) 7,070 (77.5) 6,470 (76) 5,970 (74) 5,570 (72) 5,070 (70)

5,880 (78) 5,880 (77.5) 5,480 (76.5) 5,080 (74.5) 4,780 (72.5)

6,300 (78) 6,300 (7.5) 6,000 (76.5) 5,990 (75) 5,980 (73.5) 5,510 (72) 5,010 (70)

NOTES: Radii listed are for a fully extended boom with the boom extension erected. For main boom lengths less than fully extended, the rated loads are determined by boom angle. Use only the column which corresponds to the boom extension length and offset for which the machine is configured. For boom angles not shown, use the rating of the next lower boom angle.

4,840 (78) 4,840 (77.5) 4,440 (76.5) Tipping Structure Governs Governs
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NOTE: ( ) Boom angles are in degrees.

Displays the load chart for the configuration selected on the previous slide.

LOAD

Boom Insert FS Length FS Offset Outriggers Capacity Rigging Max. Load to Lift

110 ft. 20 ft. 56 ft. 25 50% 2880 pounds 1000 pounds 1880 pounds

Config #0042 Radius 100 Boom Angle 66

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Crawler Lattice Crane

Manitowoc Model 777
200 ton capacity at 13 270 ft, Heavy-Lift Boom (HLB) 300 ft Fixed Jib on HLB 350 ft Luffing Jib on HLB Self assembly Ships on 8 trucks
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INFO

Selected Specifications
Boom No. 134 Fixed Jib
Optional: No. 134 basic fixed jib 30' length consisting of 15' jib butt and 15' jib top with 12' jib strut, pendants and backstay.

Fixed Jib

Luffing Jib

Counterweight
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Model 777 Dimensions (w/o Boom)

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Model 777 Dimensions

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Model 777 Working Range

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LOAD

Selected Model 777 Load Charts

CONFIGURATION: Luffing Jib
Boom Fixed Jib Luffing Jib

70 ft. Rotation

Length Offset None N/A Counterweight

Boom Angle Length 60 70 ft.

360 deg

142,000 lbs. Counterweight 44,000 lbs. Crawler Frame

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LOAD

Model 777 Load Chart (kips)

Radius in Feet

Luffing Jib
Main Boom Length in Feet

70 100 130 150 180

34.7 30.3 26.7 24.1 21.5 18.7 16.7 14.8 11.9 9.3

90 100 110 120 130 150 170 190

Displays the load chart for the configuration selected on the previous slide.
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Links to Manufacturers Web Pages

http://www.groveworldwide.com http://www.linkbelt.com http://www.terex.com http://www.tadanoamerica.com

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Crane Capability Evaluation

Select crane position(s) Calculate distance to
Member staging area(s) Member locations

Check load capacity at each range identify critical lifts Insure that crane can reach each location with previously placed members in place Consider multiple lift rigging
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Crane Positions
Level, solid foundation
Provided by controlling contractor, as required by OSHA

Adequate set back from slopes Consider addition of surcharge load to earth pressure on walls Protection of underground utilities/ structures Interference with other construction operations

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Plan for Crane Positions

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Office Building Case Study

Consider the Office Building Case Study [2] available from the AISC Digital Library The steel erection was performed using a Manitowoc 222 crane stationed in two different positions Multiple lift rigging was employed to improve efficiency and reduce operator fatigue Since the heaviest members weigh about 3000 lbs the crane choice will be governed 39 by the distance to the far corner

Four Story Steel Frame

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Erecting Second Sequence

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Position Relative to Building

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Multiple Lift Rigging

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Roof Framing Plan

60-4

90-8

Approx. 40 Crane Center Pin

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Example Governing Lift Evaluation

Distance to column C.G. is
(90.67 40) 2 60.332 143.9 feet

Weight of 33-6 W12X45 with attachments is determined from detailers calculations (~1700 lbs) A 19 ton capacity weight ball and wire rope for hoisting weigh 1000 lbs. The crane load chart must be checked to insure that is has adequate capacity for the total load of 2700 lbs The Manitowoc Model 222 with 160 Boom and 40 Jib at 0 Offset can lift 4400 lbs at 150 foot radius The erection sequence must be checked to insure that the crane boom wont strike other members
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Capability Evaluation Example

Consider the Office Building Case Study Assume that two cranes are available
Grove RT700E Manitowoc Model 777

Select a crane location Some details from the actual building were simplified in the model
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LOAD

Crane Model
Manitowoc Model 777 w/190ft Boom

Boom Tip Height Member Height OK

Top

139 42

Locate Crane

Group
Fourth Floor

X Y

130 -30

Radius Capacity Rigging Weight Max. Lift Load Member Weight OK

136.5 14900 2000 12900 1452

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Crane Use Optimization

Optimization in construction is generally defined in terms of minimizing cost Many second order costs will be considered in a real world problem e.g. scheduling constraints. These are beyond the scope of this presentation We will consider the fixed cost of crane mobilization and the variable cost of crew hours required for the job
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Crane Use Optimization

Mobilize Crane Fixed Cost Demobilize Crane Minimize Cost Rig/Lift Members Position Members Secure Members Return Labor Rate Reposition Time
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Crane Rate Variable Cost Hoisting Time

Cycle Time

Crane Use Optimization

In a simple optimization problem, the fixed and variable costs are functions of the crane type All cranes considered must first be found capable of completing all required lifts for the erection project A crane with higher fixed costs must be able to demonstrate lower variable costs than a competing crane to be a viable option The better of two competing cranes will then be determined by the size of the job higher fixed costs will be offset by relatively lower variable costs on large jobs
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Steel Erection / Crane Cost Evaluation

The crane-dependent cost of steel erection is

C F V F Rt where C Hoisting Cost F Fixed Cost V Variable Cost R Hourly ( Daily) Cost Rate t Hoisting Time ( Hours, Days)
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Case Study
Consider two options for erecting the Four Story Office Building
A large crawler lattice crane positioned in one location A medium crawler lattice crane placed at two positions A smaller rough terrain crane that must be repositioned several times

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LOAD

Case
Model 222

Hoist Abort

Radius Boom Angle Swing Angle Max. Lift Load Rigging Weight Net Capacity Approx. Weight Percent of Capacity

83.2 64 -32.7 32700 2000 30700 2800 9

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LOAD

Steel Hoisting Cost Illustrator

Case RT700E Position Crane Time Number of Members Members / Hour 124 7.5 1 Hours Truckloads 3 Unload Hours / Truck 0.75

Sequence Number 1

Mobilize Crane
$ 3000

Position Crane
1.0 Hr

Unload Trucks
2.3 Hr

Place Members
16.5 Hr

Demobilize Crane
$ 2000

Hourly Rate

529.00 $68,100

Calculate

Total Cost

Hourly Rate Crane 300.00 Operator 50.00 Oiler 0.00 Foreman 39.00 54 Iron Workers (x4) 35.00

Jobsite Methods/Management
Safety Rigging Crew coordination Crane foundation issues

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Safety
OSHA requirements for steel erection are covered in Subpart R of Safety and Health Regulations for Construction Two sections are critical for planning crane operations
1926.752 Site layout, site-specific erection plans and construction sequence
OSHA Steel Erection eTool Site Preparation.htm

1926.753 Hoisting and rigging

OSHA Steel Erection eTool Cranes.htm
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Accidents
Crane failures can be classified as structural or tipping Tipping can be caused by overload, inadequate foundation, or wind loading Structural failure may be due to overload or lateral load Operator error can cause either failure mode Operations near power lines present additional safety hazards

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Rigging
Columns Beams Multiple Lift Rigging Statics of rigging

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Column Rigging
This column is rigged using a device that allows the iron workers to release the rigging from the ground by pulling on the rope

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Beam Rigging
Beams are usually lifted using a choker wrapped around the beam at the center of gravity Beams may also be hoisted with two cables

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Multiple Lift Rigging

Multiple Lift Rigging is used to increase productivity and reduce crane operator fatigue OSHA Subpart R has specific requirements when using this approach
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Statics of Rigging
Lifting a beam or column using a single cable is simply a problem of selecting a cable that can support the weight and attaching it at the center Some situations will require the rigger to calculate
Center of gravity Load in skewed cables Variable sling lengths Spreader bar design
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LOAD

Statics of Rigging
1500 lbs

11'

15.56' 954.6 lbs. 1066.0 lbs.

14.21'

/\ \/
Spreader Compression 675.0 lbs.

+ C.G.

20 ft. @ 50 lb/ft 500 lb weight

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< >

Crew Coordination
Typical erection crew
Crane operator Oiler (not required on hydraulic cranes) Foreman Four ironworkers 2 ground, 2 connectors

Order of assembly is determined in advance Crane operator may be guided by hand signals or two-way radios when visibility is inadequate
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Crane Foundation Issues

Outrigger loads must be distributed over an area large enough to avoid overloading the soil Crane outriggers and tracks should be sufficiently offset from the base of slopes, excavations and retaining/basement walls Damage to underground utilities and structures from crane loads must be avoided Site soil conditions must be thoroughly evaluated before using a crane
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LOAD

Soil Bearing Load Calculator

Track Pressure (kips/sf)
Crane Type 86 0 57

Crawler 130 Boom Length (ft.) Radius (ft.) Swing Angle Load (kips)
Calculate

< < <

> > >

0.00

25.77

0.00
Firm

25.77

Soil Type Soil State

Gravel

sand and gravel

Approx. unit weight, 120 lb/cf

Presumptive Bearing Capacity for Cranes

12 ksf
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Crane and soil properties were found in Ref. [4]

Slopes, Excavations and Walls

Loads from outriggers and tracks can cause shear failure near a slope Backfilled soil can be expected to have much lower bearing capacity Walls can be damaged by surcharge loads from cranes transmitted through the soil Cranes should be offset 1.5 feet* from the toe for every foot of excavation depth *Can vary due to soil type and moisture content
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Slopes and Excavations

Outrigger Load

1 1 1.5 Preferred

In 1 good soil

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Option for Walls

1 1.5 Preferred

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Summary
Proper crane selection and application is essential for a safe and economically competitive steel erection plan The crane must be placed on stable foundations and have adequate range and lift capacity to make the required placements

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References

[1] AISC (2005) Jobsite Layout, Mobilization, Equipment and Coordination, American Institute of Steel Construction, Inc.. Chicago, IL. [2] AISC (2003) Structural Steel Construction Process - Technical, American Institute of Steel Construction, Inc.. Chicago, IL. [3] AISC (1999) Construction Management of Steel Construction, American Institute of Steel Construction, Inc., Chicago, IL. [4] Shapiro, H.I., J.P. Shapiro and L.K. Shapiro (2000) Cranes and Derricks, McGraw Hill Companies, Inc., New York.

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