Construction Equipment

Management – Lifting Equipment

 Lifting Equipment
• Why are Cranes Required ?
– Moving loads from one location to another
– Installation of Equipment
• Major Crane Types
– Mobile Cranes
– Tower Cranes
• Further Classifications of cranes is indicated in Further
slides
 Lifting Equipment
• Basic Working Principle of a Crane
– The Concept of Mechanical Advantage
• Consider a simple lever balanced on a fulcrum/pivot as
shown below

Image source - Wikipedia

 Lifting Equipment
• Basic Working Principle of a Crane
– The Concept of Mechanical Advantage
• When, a = b, then equal loads at both ends are required in
order to balance the lever. What if Load B is taken away from
the fulcrum to such a distance b so that the lever is again
balanced (with unequal loads).
• We know that since the lever is balanced, the moments on
both sides of the fulcrum is equal. In other words,
Axa=Bxb
or A = B(b/a)
Meaning, Force B (Considered as input Force) is
amplified by the ratio (b/a) in order to get A.
• This factor (b/a) is called the mechanical advantage
Lifting Equipment
• Basic Working Principle of a Crane
– Potential Energies
• In the lever that was considered in the previous example, let a = 1m
and b= 4m. Then, as per the principle of Mechanical Advantage, A =
4B, or Mechanical Advantage = N = 4
• Consider that the load B is raised by 4 mm. To what extent the Load
A moves ? (Say x)
• W.k.t, the potential energies of both Load A and B are equal at any
point of time, i.e.,
Pa = Pb
Pa = A*x and Pb = B*4
A*x = B*4
or 4B*x = B*4
x = 1 mm
• In general if N is the Mechanical Advantage, then the displacement
at the larger load end will be h = H/N.
– Where, H is the displacement at the lower Load end
 Lifting Equipment
• Basic Working Principle of a Crane
– Concept Extended to a Pulley

Image source - Wikipedia

 Lifting Equipment
• Basic Working Principle of a Crane
– The concept of lever is extended to that of a Pulley
and Load system
– The Mechanical Advantage is obtained by knowing
the number of loops around the pulley
– In case of the pulley as shown in the previous slide,
N=2
– If the load is to be lifted by 2 mm (h), then the
other end of the pulley should be pulled by N*h
times, i.e., 4 mm
 Lifting Equipment
• Hydraulic Crane Working Principle
– Concept of Pascal’s Principle
• Pressure is transmitted undiminished in an enclosed
static fluid.
 Lifting Equipment
• Hydraulic Crane Working Principle
– Hydraulic Press
 Lifting Equipment
• Numerical Examples
– Sample Problem from Note Ref – 1
• Instead of Oil, why cant air be used as a fluid ? Or water ?
– Air
• Compressible, hence lower Reaction Time
• Heat generated gets dissipated faster
• Leakage issues not clearly visible
– Water
• Corrosion problems
• Fire Resistant
• Eco-friendly
• Freezing and evaporation
– Oil
• A natural lubricant
 Lifting Equipment
• Basic Parts of a Crane
 Lifting Equipment
• Mobile Cranes
– Basic categories of Mobile Cranes generally used in
construction
• Based on Mounting Arrangement
– Crawler Mounted
– Truck Mounted
 Lifting Equipment
• Crawler Mounted Cranes
– Fully revolving superstructure
– Crawler Tracks provide stability and hence these cranes
can work without outriggers
– Has good flexibility to move around in a rugged
construction site and performs each lift with little set-
up arrangements
– Weight of the crane is spread over a large area because
of the large contact area and hence can work at site
without much risk of sinking in case of soft soils
– Difficulties in transporting the crane is a big
disadvantage. Requires considerable dismantling and
assembling
 Lifting Equipment
• Crawler Mounted Cranes
– In cases of risk of ground settlement, machines are to
be positioned and leveled on mats
– A crawler crane features either a box or a lattice type
straight boom and it may be equipped with an optional
jib (boom extension)
– Most crawler cranes have fixed length lattice boom
which is cable suspended
– Lattice being cable suspended is compression member
& not under bending as in telescopic hydraulic boom
– Suitable for long term deployment at the project site
 Lifting Equipment
• Truck Mounted Cranes
– Minimum dismantling and reassembling, meaning
lesser set up costs
– Fully revolving superstructure
– Motorable on highways and hence transporting is not a
big problem – Draws power from only one engine for
both crane part and truck part (in case of large capacity
cranes separate engines are available)
– For heavy lifts, solid ground and perfect outrigger
positioning is required. However this occupies a lot of
space, which is a big draw back
– Well suited for small duration projects
 Lifting Equipment
• Mobile Cranes
– Basic categories of Mobile Cranes generally used in
construction
• Based on Boom Type
– Telescopic Boom
– Lattice Boom
 Lifting Equipment
• Telescopic Boom Cranes
– Telescopic booms are heavier when compared to a
equivalent capacity lattice boom cranes
– The boom is made up of many tubes fitted inside one
another that can be extended through hydraulics
– Some of the telescopic cranes are equipped with a jib
on top so that they can perform as a tower crane also
– Telescopic cranes offer a very speedy set up, making
them perfect for emergency or rescue jobs
– They can place heavy loads with exactitude whilst being
easily maneuverable and able to reach up high
– Outrigger space constraint is a disadvantage
– Telehandler is a variant with similar functions
 Lifting Equipment
• Telescopic Boom Cranes
– Largest Telescopic Boom Crane in the World
 Lifting Equipment
• Telescopic Boom Cranes
– Telehandler
• Man lifting and works with lower loads
 Lifting Equipment
• Lattice Boom Cranes
– Light weight. Hence same mounting arrangement
can carry higher capacity cranes when compared to
Telescopic crane mounting arrangements
– Mostly the lattice boom has to be dismantled
during transportation. This requires another crane
for handling. Also time consuming process
– Unlike a telescopic boom crane,
the length of boom cannot be
changed easily. Some cranes
are equipped with boom
extensions or fly jibs
 Lifting Equipment
• Lattice Boom Cranes
– Largest Lattice Boom Crane in the World
 Lifting Equipment
• Mobile Cranes
– Basic categories of Mobile Cranes generally used in
construction
• Based on Outrigger Type
– Hydraulic Outriggers
 Lifting Equipment
• The Outriggers
– Outrigger is the most critical part of a crane. It transfers
load of crane and its load on to the ground.
– Lot of accidents do happen due to improper outrigger
set up
– Agencies like OSHA, ASME etc have laid down certain
safety requirements for safe handling of cranes with
outriggers
• Cranes must be assembled on ground that is firm, drained and
graded sufficiently, in conjunction with supporting materials,
such as blocking, cribbing, pads, mats, to provide adequate
support and levelness (OSHA 1926.1402)
Lifting Equipment
• The Outriggers
– Crane Set-up
• Cranes must be assembled on ground that is firm,
drained and graded sufficiently, in conjunction with
supporting materials, such as blocking, cribbing, pads,
mats, to provide adequate support and levelness (OSHA
1926.1402)
– Blocking is commonly used to provide a foundation for heavy
loads such as outriggers.
– Cribbing is used when a heavy load must be supported at a
height greater than blocking can provide
– Padding
• Know the bearing strength of the ground and soils.
Lifting Equipment
• The Outriggers
– Crane Set-up
• Identify any sub-surface hazards and avoid if possible
• Improve the SBC of the ground if possible and required
• Know the maximum Load the outriggers. Check crane
manufacturer data for this information
• Calculate the sizing requirements. Do not go by thumb
rules only
• Never place blocking, cribbing, pads or mats under the
outrigger beam. Only use them under the outrigger
floats
Lifting Equipment
• The Outriggers
– Crane Set-up
• Monitor every lift. If the outrigger pad or crane mat is
deflecting or bending, stop the lift. If the pad or mat is
being driven into the ground, stop the lift. The load
pressure is in excess of the ground bearing pressure. A
larger surface area or improved ground conditions are
needed to support the load
Lifting Equipment
• The Outriggers
– Sizing
• The area required for blocking/cribbing will be
Total Load (including the load to be lifted, accessories etc)/SBC of
the soil
– Note – Be very careful about the units
– DO NOT DIVIDE THE TOTAL LOAD BY NO. OF OUTRIGGERS TO
ARRIVE AT THE LOAD ON EACH OUTRIGGER IN ORDER TO
CALCULATE THE SIZING
• Sample Problem
 Lifting Equipment
• Mobile Cranes
– Basic categories of Mobile Cranes generally used in
construction
• Based on Jib Type
– Fixed Jib
– Luffing Jib
 Lifting Equipment
• Mobile Cranes
– Jib
• A fixed jib is a horizontal member of a crane to which the
movable hoist is attached
• A fully fixed jib does have movement in vertical and
horizontal directions
• A jib can have a horizontal movement or a vertical
movement or both
• The image on the left shows a simple Jib Crane
 Lifting Equipment
• Mobile Cranes
– Basic categories of Mobile Cranes generally used in
construction
• Other Types
– Rough Terrain/All Terrain Cranes
 Lifting Equipment
• Mobile Cranes
– Rough Terrain Cranes
• Fitted with a two-axle carriers
• Simpler design and lower cost
• Large wheels, closely placed axles and helps in improved
maneuverability and high ground clearance
• 18- 50 tons capacity
• Cherry Pickers are a variant
• Typically employed as utility machines
• Cannot travel at speeds more than 30 mph
• Requires a lowboy for long distance highway travel
 Lifting Equipment
• Mobile Cranes
– All Terrain Cranes
• All axle drive, dual cabs
• Excellently suited for highway travel hence very helpful
in case of scattered projects and a single project spread
out over a large area
• Higher cost than a rough terrain truck
• Does not need a lowboy for long distant travel
• Does not need other construction equipment to make
way for its movement and positioning
• Lifting range up to 65 MT
 Lifting Equipment
• Modifications for Increased Lifting Capacity
– Lifting Capacity of a crane is mainly dependent on two
factors
• Structural Strength
• Tipping Factor
– A counterweight is used to avoid tipping
– When a counterweight is added during heavy lifts,
during instances of no load or reduced load, there is a
danger of the crane tipping backward
– Even with sufficient counterweight, the boom will be
subjected to such a compression that it may fail
– Cranes now come with technology to provide such
heavy lifting capability that machine integrity is also
maintained during instances of heavy lifting
 Lifting Equipment
• Modifications for Increased Lifting Capacity
– Four such systems/technologies are available
• Trailing counterweight
– Base crane does not carry the counterweight. It is available on
the wheeled platform connected to the crane with a platform pin
• Extendable counterweight
– This counterweight system can be extended away from the rear
of the machine to match with the leverage of the lift
• Ring System
– Has a large circular turnable ring outside the base machine
connected to the base at the front and rear with pins. The base
crane is only a power and control source. Lesser mobility is a
disadvantage
• Guy derrick
– High vertical mast will be tied off with guy cables. Renders the
crane immobile
 Lifting Equipment
• Modifications for Increased Lifting Capacity
– Four such systems/technologies are available
• Guy derrick
 Lifting Equipment
• Calculating the lifting capacities of Cranes
– Lifting capacities of Cranes are calculated by referring
the load charts that comes with every crane
– If load charts are not referred before selection of a
Crane, then the planner ends up in selecting an
undersized or an oversized crane, unfit and
uneconomical for the purpose
– Knowledge of the load chart is essential to Crane
operators, work supervisors, renting/sales agents,
planning engineer, maintenance team, Safety
inspectors and Quality team
 Lifting Equipment
• Calculating the lifting capacities of Cranes
– The lifting capacity that is calculated, is based on ideal
conditions, to avoid tipping of the crane
– Other conditions that affect this factor are,
• Wind Forces on the boom or load
• Swinging of the load
• Hoisting speed
• Stopping the hoist
– safety regulations limit maximum crane load to a % of the
tipping load
• Tipping load - load that will cause the crane to actually begin to tip.
• Tipping load includes the weight of the item being lifted, weight of
hooks, hook block, rope etc & any other item used in hoisting the
load.
 Lifting Equipment
• Calculating the lifting capacities of Cranes
– Basic parameters

• Boom length A

• Radius of Load B

• Boom Angle C
 Lifting Equipment
• Calculating the lifting capacities of Cranes
– Other factors

• position of the boom in relation to the carrier

• whether or not out riggers are used

• the amount of counter weight

• condition of the supporting surface

 Lifting Equipment
• Calculating the lifting capacities of Cranes
– Points to be noted while referring the Load Charts
• Loads indicated are Gross Capacities. The actual mass of
the load is called the Net Capacity. The difference
consists of the loads from blocks, hooks and slings.
These are also known as Capacity Deductions
• Gross Capacity – Capacity Deduction = Net Capacity
• Always read the manufacture notes before referring the
chart. Certain conditions may differ from manufacturer
to manufacturer
• Jib, fly or boom extensions are same terms
 Lifting Equipment
• Calculating the lifting capacities of Cranes
 Lifting Equipment
• Calculating the lifting capacities of Cranes
 Lifting Equipment
• Calculating the lifting capacities of Cranes
 Lifting Equipment
• Calculating the lifting capacities of Cranes
 Lifting Equipment
• Calculating the lifting capacities of Cranes
 Class Problem : Crane Selection
This range dig. For TIL
crane. You need to pick
up a load at 20 m radius
and lift it to the top of a
building at 18m height.
Consulting the range
diagram, find out min.
boom length to make the
lift.

The required min boom

length falls in between the
working envelope of 24.4 &
27.4 m boom lengths so
considering the next
available length, 27.4 m
boom to be used.
 Class Problem : Crane Selection
METRIC 85% LIFTING CAPACITIES (KILOGRAMS)
ON OUTRIGGERS FULLY EXTENDED

The Crane TMS 750B is

set up as follows:
1. 15.2m of boom.
2. Working radius4 m.
3. 400 kg hook block.
4. 300 kg Lifting
slings.
5. Outrigger full
extended.

What is the max load crane

will lift

= 24300-400-300
= 23600 kg
 Class Problem : Crane Selection
• Determine the minimum boom length that will permit the
crawler crane to lift a load which is 34 ft high to a position
114 ft above the surface on which the crane is operating.
The length of the block, hook, and slings that are required
to attach the hoist rope to the load is 26 ft.
• The location of the project will require the crane to pick up
the load from a truck at a distance of 70 ft from the
center of rotation of the crane. If the block, hook, and
slings weigh 5,000 lb, determine the maximum net
weight of the load that can be hoisted.
 Class Problem : Crane Selection
• FIG-1

Working Ranges for a

200-ton Crawler
Crane (Manitowoc Eng.
Co)
 Class Problem : Crane Selection
Table 1. Lifting Capacities (lb) for 200-ton Crawler Crane with 180 ft of Boom
 Class Problem : Crane Selection
• The operating radius = 70 ft
• Total height of boom point = 114 + 34 + 26 = 174 ft
• From Figure 1, for a radius of 70 ft, the height of the boom point is 178 ft for
180-ft boom, which is high enough.
• From Table1 for 180-ft boom and 70-ft radius, Maximum total load = 47,600 lb
• Hence
• Maximum Safe Weight = 47,600 - 5,000 = 42,600 lb
 Lifting Equipment
• Tower Cranes
– Used when space is Restricted
– Can reach to varying heights
– Moving counterweight balances load
– Can have Fixed foundation or Crawler attachment
– Tower cranes widely used on building construction projects
because of its wide operating radius, and almost unlimited
height capability
– Majority of tower cranes are of the saddle-jib or horizontal
boom type
 Lifting Equipment
• Tower Cranes
– Luffing jib (inclined boom) models are available which
have the ability to operate in areas of restricted
horizontal clearance not suitable for conventional
tower cranes with their fixed jibs and counter weights
– Different tower crane mounting possibilities
– Climbing cranes are supported by completed building
floors and are capable of raising themselves from
floor to floor as building is erected
– Most tower cranes can raise themselves section by
section until the mast or tower reaches the desired
height
 Lifting Equipment
• Basic Parts of a Tower Crane
– Base: The steel structure of the tower crane is bolted to
the concrete pad.
– The Mast or the Tower: Gives the height to the crane. has
guard rails and guide rails which guides the elevator the
operator and the maintenance technician
– The Slewing Unit: This is the mobile unit of the tower
crane, which is capable of rotating almost 360 degrees. It
is a set of combination of huge gears and motors which
enables the crane to slew
– On top of the slewing unit, the tower crane has three
more parts
 Lifting Equipment
• Basic Parts of a Tower Crane
– jib: One of the most important parts of a crane and in a
tower crane it extends horizontally carrying a trolley
which runs in and out of the crane’s centre carrying the
load
– The machine house: located horizontally along the line of
the jib, usually extending behind the crane’s centre. It
houses the crane’s motor and other electronic
components/safety devices along with huge concrete
counterweights. These counterweights provide balance
while lifting a load on the other side of the crane through
the jib
– Operator’s cabin: Located in such a way that none of the
crane operation would hinder his visibility
 Lifting Equipment
• Tower Cranes
– Basic categories of Tower Cranes generally used in
construction
• Based on Type of Base
– Static Base Tower Crane
– Travelling Base Tower Crane – Rail, Crawler, Truck
 Lifting Equipment
• Tower Cranes
– Basic categories of Tower Cranes generally used in
construction
• Based on Type of Boom
– Horizontal Boom Tower Crane
– Luffing Boom Tower Crane
 Lifting Equipment
• Tower Cranes
– Basic categories of Tower Cranes generally used in
construction
• Based on Slewing
– Top Slewing or Fixed Tower
– Bottom Slewing or Slewing Tower
 Tower Cranes
• Bottom slewing cranes are mostly self erecting
type
• These cranes has lower carrying capacity since the
revolving base cannot be fixed to a permanent
structure
• Top slewing cranes take more time to set-up (help
of another equipment) but can reach much greater
heights & have higher capacities
• Bottom slewing cranes are suitable for short terms
services for low rise buildings & top slewing cranes
are suitable for high rise buildings where the time
duration is also longer
Tower Cranes
61
62
 Lifting Equipment
• Tower Cranes
– Some of the tallest Tower Cranes
 Lifting Equipment
• Tower Cranes Selection
– Tower Cranes are fixed and considerable time and money is
spent in installation of a tower crane. Hence planning has to
be done for its location and type considering the following
• Weight, dimension and lift radii of the heaviest loads
• Maximum Free standing height of the tower crane
• Maximum braced height of the machine
• Machine climbing arrangement
• Weight of the machine supported by the structure
• Available headroom which can be developed (between bottom of
crane hook and uppermost area of the structure min 20 ft)
• Area that must be reached
• Hoist Speeds of the machine
• Length of the cable that the hoist drum can carry
 Lifting Equipment
• Tower Crane Selection
– Selection using a Load Chart
– 5% Factor of Safety to be added to the load (load
from rigging needs to be added)
– Sample Problems
 Lifting Equipment
• Question
– How does a Tower Crane stay balanced when
there is no load ?
 Lifting Equipment
• Rigging
– It is the work of properly tying and attaching the
load to the crane
– From the safety point of view, this is a very critical
work, as important as section of the right crane
– Rigger needs to be aware of the forces involved
while lifting
– Stress are induced due to load movement
– The forces involved will vary with the method of
connection and the effects of motion
Lifting Equipment
• Rigging
– Weight
• Have accurate details of loads to be lifted
– CG
• When the load is hooked above the CG or through the
CG, then the load will be balanced and will not sway
during lifting
– Stresses
• Use spreader bars while lifting large dimension loads to
reduce the stresses induced in the slings
Lifting Equipment
• Rigging – Stresses
Lifting Equipment
• Rigging
– Motion
• When the loads are lifted from zero to the normal speed of
ascent, additional stresses are developed
• Greater stresses are developed in cases of loads that are
accelerated quickly by mechanical power
– Always adhere to the Factor of safety mentioned in
the user’s manual
– Types of slings
• Wire Rope
• Chains
• Synthetic Web
– Sling Inspection Process
Lifting Equipment
• Types of crane accidents
 Lifting Equipment
• Crane Safety
– U.S. Occupational Safety and Health Act (OSHA)
regulations:
• Prohibit a crane or its load from approaching closer
than 10 ft (3 m) to a high-voltage line carrying 50 kV or
less
• An additional 0.4 in. (1 cm) must be added for each
kilovolt over 50 kv
 Lifting Equipment
• Crane Safety
– These safety clearances must be maintained:
• unless the line is de energized and visibly grounded at
the work site, or
• unless insulating barriers not attached to the crane are
erected which physically prevent contact with the
power line.
– Crane accidents occur all too frequently in
construction work,
• particularly when lifting near-capacity loads and when
operating with long booms.
 Lifting Equipment
• Crane Safety
– Some suggestions for safe crane operations include
the following
1. Carefully set of outriggers on firm supports.
2. The crane base must be level. Safe crane capacity is
reduced as much as 50% when the crane is out of level by
only 3o and operating with a long boom at minimum radius
3. Use a communications system or hand signals when the
crane operator cannot see the load at all times. Make sure
that all workers involved in the operation know the hand
signals to be used
4. Provide tag lines (restraining lines) when there is any
danger due to swinging loads
 Lifting Equipment
• Crane Safety
– Some suggestions for safe crane operations
include the following
• Ensure that crane operators are well trained and know
the capability of their machines
• Check safe-lifting-capacity charts for the entire range of
planned swing before starting a lift. INTERPOLATION IS
NOT ALLOWED
 Lifting Equipment
• Codal Provisions
– IS 13473 (Part 1)-1992 : Glossary of terms for cranes
– IS/ISO 4306 : Part 2 -1994 : Cranes - Vocabulary : Part 2 Mobile Cranes
– IS/ISO 4306 : Part 3-2003 : Cranes - Vocabulary : Part 3 Tower Cranes
– IS 6521 : Code of practice for design of tower
cranes
– IS6521(Part1)-1972 : Static and rail mounted cranes
– IS6511-1972 : Range of preferred safe working loads
for cranes, lifting appliances and related
equipment
– IS6717-1972 : Mobile road cranes, fully slewing
– IS4573-1982 : Power driven mobile cranes
– IS3443-1980 : Crane rail section
 Lifting Equipment
• Other Misc. Lifting Equipment
– Hoists
• Small equipment used for hoisting loads generally up to 80T
• It can be either hand operated or powered.
• Available in capacities from 0.25T
• Extremely portable & hence popular on all construction sites
across sectors
• Example – Chain Hoists
• Construction hoists are used to lift people or materials to
various heights alongside a building or structure being built
• Other Type of Hoists
Lifting Equipment
• Other Misc. Lifting Equipment
– Hoists
Lifting Equipment
• Other Misc. Lifting Equipment
– Gantry Cranes
• Used in outdoor applications where lifting facilities are
provided without the cost of a building or any
supporting steelwork
• They are also suited to indoor applications where
existing building structures are not suitable to take
overhead cranes
• Cranes can be constructed with a cantilever to allow
handling outside the rail centers
• Typical applications for this type of crane include steel
stock yards, loading areas, and ship building
Lifting Equipment
• Other Misc. Lifting Equipment
– Gantry Cranes
Lifting Equipment
• Other Misc. Lifting Equipment
– Fork Lifts
Lifting Equipment
• Ropes
• Winches
• Sheaves