TS12 Tower Erection

1 ERECTION AND DISMANTLING PROCESS

1.1 GENERAL
1.2 SAFETY PRECAUTIONS
1.3 JOB SITE PREPARATION AND REQUIREMENTS
2 ERECTION
2.1 GROUND ASSEMBLY
2.1.1 Assembling undercarriage C32 (3.2×3.2 /10×10 ft)
2.1.2 Assembling undercarriage C38 (3.8×3.8 / 12×12 ft)
2.1.2.1 Connecting the travelling kit (Installation “T”)
2.1.3 Assembling the tower sections
2.1.3.1 Assembling tower sections TS12 22.3 DX (code111641220)
2.1.3.2 Assembling tower sections TS12 22.3 SX (code111641221)
2.1.3.3 Assembling platforms for tightening of bolts of lower slewing ring support
2.2 ERECTION BY MOBILE CRANE
2.2.1 Positioning subundercarriage ballast blocks (Installation “FP” )
2.2.1.1 Undercarriage C32 TS12 FP (base ballast IR “A” )
2.2.1.2 Undercarriage C38 TS12 FP
2.2.2 Positioning undercarriage C32
2.2.2.1 Installation “F” - “T”
2.2.2.2 Checking the level (Installation “FP”)
2.2.2.3 Checking the level (Installation “F”)
2.2.2.4 Positioning the base ballast
2.2.2.5 Access ladder assembly
2.2.3 Positioning undercarriage C38
2.2.3.1 Installation “F” - “FP” - “T”
2.2.3.2 Checking the level (appoggio “FP”)
2.2.2.3 Checking the level (appoggio “F”)
2.2.3.4 Checking the level (appoggio “T”)
2.2.3.5 Positioning the base ballast
2.2.3.6 Access ladder assembly
2.2.4 Assembling the tower
2.2.4.1 Assembling tower TS12 / 12-6-3 m (39-20-10 ft)
2.2.4.2 Assembling tower TS12 12.12 / 22.12
2.2.4.3 Assembling tower TS12 12.6 / 22.6
2.2.4.4 Assembling tower TS12 12.3 / 22.3
2.2.4.5 TS12 Tower connection
2.2.4.6 Connecting the tower sections
2.2.4.7 Tensioning order for the bolts connecting tower sections, anchor plates, undercarriage and
TS12 lower slewing ring support
2.2.5 Final checks
3 DISMANTLING
3.1 REQUIREMENTS FOR DISMANTLING
3.2 DISMANTLING THE TOWER
3.3 DISMANTLING THE UNDERCARRIAGE
3.4 CRANE STORAGE

Chapter 4 B
4B_TS12_000_e
1 ERECTION AND DISMANTLING PROCESS

1.1 GENERAL

The erection and dismantling of the crane shall be done by skilled technicians, who have attended
a specific training course.

F Crane users are advised to contact Comedil after-sales Service or Comedil agents for qualified
erectors.
Should the user employ other erectors, their ability shall be verified before handling the crane.
In this case, Comedil declines any criminal and public liability.

For the crane erection and dismantling at least three skilled technicians are needed: two
responsible for the assembly by mobile crane, one for the co-ordination of the operations
on the ground.

1.2 SAFETY PRECAUTIONS

The erector shall observe the following safety precautions before starting the erection or dismantling
of the crane:
A) he shall not work in inclement weather
conditions;
B) he shall work in perfect psychophysical
conditions and check that the individual and
personal accident prevention devices are 
available and serviceable;
C) he shall wear a type approved safety helmet
which is integral;
D) he shall wear a type-approved safety belt
which is integral;
E) he shall wear accident-prevention shoes;
F) he shall use tools equipped with electric
insulation;
G) should the components pre-assembled on
the ground be wet or damp, he shall be
careful when carrying out the erection of the
crane by mobile crane;
H) for the safety of people and equipment, the
erector shall check that barriers are placed
around the assembly and disassembly area
and that there are no unauthorized people
inside the working area.

Picture 1.2.1

Page 3/23 TS12 Tower Erection 4B_TS12_000_e

 1.3 JOB SITE PREPARATION AND REQUIREMENTS

Before starting work, the crane erector shall inspect the job site for proper arrangement. The people
in charge of the job site preparation shall be advised about any default found, thus allowing them to
remedy it.
Erection of the tower shall start after the erector has checked that:
A) the maneuvering area of the crane is free from obstacles (trees, buildings, electric lines,
telephonic lines, etc.);
B) the curing time of the concrete bed, of the base and of the ballast is adequate;
C) base ballast and test loads satisfy the manufacturer’s specifications;
D) the electric connections are adequate;
E) the hoisting equipment available at the job site is suitable for the work to be carried out;
F) proper slings or other lifting attachments are being used.

MOBILE CRANE SPECIFICATIONS

The appropriate mobile crane for the crane tower erection shall be chosen according to:
ð the crane installation type (“R” - “F” - “FP” - “T”)
ð the tower height
ð the crane model (slewing upper part)

F
For a correct choice refer, therefore, to Chapters 4A “Tower - Dimensions & Weights”
and 5A “Slewing Upper Part - Dimensions & Weights” of the crane operation manual,
as well as to the recommended assembly procedure illustrated in the following pages.

The erector shall inform the mobile crane operator of the exact weight of the parts to be
lifted.
The mobile crane operator shall see that the load is well secured and balanced in the sling
before it is lifted.

4B_TS12_000_e TS12 Tower Erection Page 4/23

 2 ERECTION
2.1 GROUND ASSEMBLY

Pay attention to the mounting holes of the elements to be assembled which shall be visually
inspected for impurity and possible paint traces. Pins and mounting holes shall be properly
greased before assembly.
All pins shall be secured by the proper spring split pins or pin lock plates.
All bolt-connections shall be free from paint on the connecting surfaces.

2.1.1 Assembling undercarriage C32 (3.2×3.2 m / 10×10 ft)

On placing beam-A on the ground (expected to lie on some wooden shims), sling and lift beam-B
off the ground. Position it inside beam-A at right angle, thus allowing the Ø75-pin holes on the two
beams to coincide.
The adjusting M18 and M27 screws located beneath the holes shall make this operation
easier (picture 2.1.2).
Position CS 75×455 pins and secure them with 16×140 split pins.

beam A Beam “A” WEIGHT

1430 kg (3153 lbs)

beam B
Beam “B” WEIGHT
1387 kg (3058 lbs)

Picture 2.1.1

CS75×455 pin
M27×90 screw
16×140 split pin D
beam B
M18×90 screw
M18 tall nut

beam A D Picture 2.1.2

Section D-D

Page 5/23 TS12 Tower Erection 4B_TS12_000_e

 Assemble tower access platform (1) on the undercarriage securing it with the proper M10×35
screws and relative split pins and nuts (picture 2.1.3).

1
Picture 2.1.3
M10×35 screw
M10 tall nut
M10 washer

2.1.2 Assembling undercarriage C38 (3.8×3.8 m / 12×12 ft)

F Information not available.

Consult Comedil’s Technical Department.

2.1.2.1 Connecting the travelling kit (Installation“T”)

F Information not available.

Consult Comedil’s Technical Department.

4B_TS12_000_e TS12 Tower Erection Page 6/23

2.1.3 Assembling the tower sections

2.1.3.1 Assembling tower sections TS12 22.3 DX (code111641220)

Assemble the rest platform, the ladder and the protection on tower element (1) using M12×35
screws with relative nuts and washers. Make sure that they are positioned correctly about the
tower lugs (picture 2.1.4).

Y Y

“R” VIEW

SECTION Y-Y

PROTECTION

LADDER LUGS

R
REST
PLATFORM

Picture 2.1.4

Page 7/23 TS12 Tower Erection 4B_TS12_000_e

2.1.3.2 Assembling tower sections TS12 22.3 SX (code111641221)

Assemble the rest platform, the ladder and the protection on tower element (1) using M12×35
screws with relative nuts and washers. Make sure that they are positioned correctly about the
tower lugs (picture 2.1.5).

Y Y

“R” VIEW

SECTION Y-Y

PLATFORM
LADDER
LUGS

R
PROTECTION

Picture 2.1.5

F NOTE
6 m (20 ft) and 12 m (39 ft) TS12 tower elements are delivered to the job site already
assembled with rest platforms, ladders and protections.

4B_TS12_000_e TS12 Tower Erection Page 8/23

2.1.3.3 Assembling platforms for tightening of bolts of lower slewing ring support

Assemble the platforms for tightening M48 bolts connecting the tower section and the lower slewing
ring support on the top tower section, near the diagonal, at about 1.5 m (5 ft) from the top tower
section edge (pictures 2.1.6 and 2.1.7).
On tightening the bolts, if the crane is not equipped with control cab, the platforms can stay in
horizontal working position.
Otherwise, rotate them so as to avoid dangerous interference during the crane slewing.

F Rotation of the platforms is carried out removing the proper pin (picture 2.1.7).

Lower slewing ring

support

Cab

TS12
Tower
Platform for bolts
tightening

Picture 2.1.6

Pin Platform for bolts

TS12 tightening
tower

TS12 tower
Picture 2.1.7
stanchion

Page 9/23 TS12 Tower Erection 4B_TS12_000_e

 2.2 ERECTION BY MOBILE CRANE

IMPORTANT ADVICE FOR ERECTION BY TOP CLIMBING UNIT

When top climbing (raising the tower by telescoping section), make sure thet the tower lugs (1) are
positioned as shown in picture 2.2.1.

consult Comedil

BUILDING

1 A 1

View A
1

Picture 2.2.1

All bolt connections shall be free from paint on the connecting surfaces.

During this phase the erection personnel shall strictly observe the provisions stated in the
92/58/EEC standards as for signalling and safety on the job site. Therefore, he shall keep
continuous visual contact with the crane operator.

4B_TS12_000_e TS12 Tower Erection Page 10/23

 2.2. Positioning subundercarriage ballast blocks (Installation “FP” )

2.2.1.1 Undercarriage C32 TS12 FP (ballast IR “A”)

On checking the soil for proper level (use concrete, as necessary) and resistance, position
four IR “A” ballast blocks respecting the center-to-center distance and diagonal shown in picture
2.2.2.

Unitary weight= 2500 kg (5513 lbs) 4.

52
3.2 m (10 ft) - undercarriage C32 (3.2×3.2 m /10×10 ft) m
(1
5
ft)
- un
de
rc
ar
ria
ge
C
32
(3
.2
×3
.2
m
/1
0×
10
ft)
ft)
0
0×1
/1
m
2
×3.
.2
(3
32
C
e
riag
3.2 m (10 ft) - undercarriage C32 (3.2×3.2 m /10×10 ft) r
rca
e
und
-
ft)
5 Picture 2.2.2
(1
m
.52
4

2.2.1.2 Undercarriage C38 TS12 FP (ballast______)

F Information not available.

Consult Comedil’s Technical Department.

Page 11/23 TS12 Tower Erection 4B_TS12_000_e

2.2.2 Positioning undercarriage C32

2.2.2.1 Installation “F” - “FP”

Sling, lift and position undercarriage (1) on screw jacks (2) or on ballast blocks (3) securing it with
the proper M30×120 screws, relative nuts and washers (installation “F” ) or with washers and
M24 tall nuts (installation “FP” ) (picture 2.2.3).

WEIGHT OF THE UNIT

2833 kg
(6247 lbs)

M24 tall nut

M24 washer
M30×120
screw 3

Undercarriage C32 - 3.2 m (10 ft)

Eyebolts

Undercarriage C32 - 3.2 m (10 ft)

Picture 2.2.3

4B_TS12_000_e TS12 Tower Erection Page 12/23

2.2.2.2 Checking the level (installation “FP”)

Having assembled the undercarriage check it for proper alignement and plumbing on both ways.
The tower shall be erected plumb to a tolerance of 1:400 mm (about 1 in. in 32 ft).
Should the value prove different, contact Comedil Technical Department.

2.2.2.3 Checking the level (installation“F”)

1
Check the correct levelling of the undercarriage
acting on the four threaded screw jacks (1) for
any adjustments (picture 2.2.4).
Picture 2.2.4
Carry out the adjustment with the undercarriage
slightly off the ground.

The tower shall be erected plumb to a tolerance of 1:400 mm (about 1 in. in 32 ft).
Should the value prove different, contact Comedil Technical Department.

2.2.2.4 Positioning the base ballast

F As regards the configuration and quantity of the base ballast to be placed on the undercarriage
(installation “F” - “FP”) see Chapter 3C- “Tower installation F - FP - T ” of the crane
operation manual.

2.2.2.5 Access ladder assembly

A special ladder (picture 2.2.5) makes the access to the tower easier.
The ladder is secured to the tower section crossbeam with M10×35 screws and relative nuts and
washers.

SEZ. L-L
SEC. L-L

M10×35 screw

Tower section
crossbeam
L ladder

ladder
Picture 2.2.5

Page 13/23 TS12 Tower Erection 4B_TS12_000_e

2.2.3 Positioning undercarriage C38

2.2.3.1 Installation “F” - “FP” - “T”

F Information not available.

Consult Comedil’s Technical Department.

2.2.3.2 Checking the level (Installation“FP”)

Having assembled the undercarriage, check it for proper alignement and plumbing on both ways.
The tower shall be erected plumb to a tolerance of 1:500 mm (about 1 in. in 40 ft).
Should the value prove different, contact Comedil Technical Department.

2.2.3.3 Checking the level (Installation “F”)

F Information not available.

Consult Comedil’s Technical Department.

2.2.3.4 Checking the level (Installation “T”)

F Information not available.

Consult Comedil’s Technical Department.

2.2.3.5 Positioning the base ballast

F As regards the configuration and quantity of the base ballast to be placed on the undercarriage,
refer to Chapter 3C - “Tower installation F-FP-T” of the crane operation manual.

2.2.3.6 Access ladder assembly

F Information not available.

Consult Comedil’s Technical Department.

4B_TS12_000_e TS12 Tower Erection Page 14/23

2.2.4 Assembling the tower
2.2.4.1 Assembling tower TS12 / 12-6-3 m (39-20-10 ft)
Assemble the tower making sure that the rest platforms and the ladders connecting the single
tower elements are turned 180° one about the other as shown in picture 2.2.6.
Place “NO ENTRY” safety sign (3) on TS12 tower section.

F As regards the assembly of support frame (1) and electrical box (2) refer to chapter 4C-
“Electrical equipment location” of the crane operation manual.

SEZ. Y-Y
Y Y SEC. Y-Y

TS12 22.3 / 12.3

SEZ. Y-Y
Y Y SEC. Y-Y

TS12 6.12 / 12.6

Y1 Y1 SEZ. Y-Y
SEC. Y-Y

SEZ. M1-M1
M1 M1 SEC. M1-M1

TS12 22.12 / 12.12

SEZ. Y-Y
Y Y SEC. Y-Y
2

M M SEZ. M-M
SEC. M-M

Picture 2.2.6

Page 15/23 TS12 Tower Erection 4B_TS12_000_e

2.2.4.2 Assembling tower TS12 12.12 / 22.12
Assemble the tower making sure that the rest platforms and the ladders connecting the single
tower elements are turned 180° one about the other as shown in picture 2.2.7.

SEZ. Y1-Y1
Y1 Y1 SEC. Y1-Y1

SEZ. M1-M1
M1 M1 SEC. M1-M1

SEZ. Y-Y
TS12 22.12 / 12.12 Y Y SEC.Y-Y

M M SEZ. M-M
SEC.M-M

Y1 Y1 SEZ. Y1-Y1
SEC.Y1-Y1

SEZ. M1-M1
M1 M1 SEC.M1-M1

SEZ. Y-Y
TS12 22.12 / 12.12 Y Y SEC.Y-Y

M M SEZ. M-M
SEC.M-M

Picture 2.2.7

4B_TS12_000_e TS12 Tower Erection Page 16/23

2.2.4.3 Assembling tower TS12 12.6 / 22.6
Assemble the tower making sure that the rest platforms and the ladders connecting the single
tower elements are turned 180° one about the other as shown in picture 2.2.8.

SEZ.Y-Y
Y Y SEC.Y-Y

TS12 22.6 / 12.6

SEZ.Y-Y
Y Y SEC.Y-Y

TS12 22.6 / 12.6

SEZ.Y-Y
Y Y SEC.Y-Y

TS12 22.6 / 12.6

Picture 2.2.8

Page 17/23 TS12 Tower Erection 4B_TS12_000_e

2.2.4.4 Assembling tower TS12 12.3 / 22.3
Assemble the tower making sure that the rest platforms and the ladders connecting the single
tower elements are turned 180° one about the other and that the assembly lugs are positioned all
in the same direction (picture 2.2.9).
To this purpose, assemble alternatively a right (DX) and a left (SX) tower element.

lugs

Y Y
SEZ.Y-Y
SEC.Y-Y

TS12 22.3 / 12.3 DX

lugs

lugs

Y Y SEZ.Y-Y
SEC.Y-Y

TS12 22.3 / 12.3 SX

lugs

Y Y SEZ.Y-Y
SEC.Y-Y

TS12 22.3 / 12.3 DX

lugs

Picture 2.2.9

4B_TS12_000_e TS12 Tower Erection Page 18/23

2.2.4.5 TS12 Tower connection

The connection of TS12 tower sections consists of two M48×3 bolts (Comedil design) placed on
each stanchion.
The screw grade is 10.9 (marking on the screw head); the nut grade is 10 (side marking).
Use Comedil original bolts only.
The assembly of TS12 tower connections should be carried out with the maximum care. A designated
person shall examine these connections for deficiencies at periodic intervals so as to determine if
they constitute a hazard.
All bolt connections tightened by tensioning tools, electrical or hydraulic wrenches shall
be subject to periodical visual examinations by a qualified person to verify their proper
installation and prevent them from loosening.

2.2.4.6 Connecting the tower sections

Visually inspect the connection surfaces between the mast section stanchions for paint
traces or other impurities, the connection surface supporting either nuts and screw heads,
and the threads of screws and nuts.
Lubricate the nut and screw threads, the nut and the screw head bearing surfaces using
MoS2-based greases (fig. 2.2.11).
The non-observance of this precautionary measure could result in the bolts loosening
after their tightening.

Place the bolt in the connection hole with the screw head upward and the nut downward.

F The torque wrench setting for M48 bolts (TS12 tower) should be about 3000 Nm (2313 ftlbs) for
22.12, 22.6 and 22.3 tower elements and about 2400 Nm (1770 ftlbs) for 12.12, 12.6 and 12.3
tower elements.

The recommended torque setting can be achieved using an electrical (picture 2.2.12) or hydraulic
wrench, maybe even a hammer wrench (manual tightening). If so, use a 5 kg (11 lbs) hammer
(picture 2.2.11).
For the two internal bolts, use also the special extension supplied (picture 2.2.13).

Picture 2.2.11

Picture 2.2.10 Picture 2.2.13

Picture 2.2.12

Page 19/23 TS12 Tower Erection 4B_TS12_000_e

 On completing tightening, place the special lock-ring nut on M48 screw head. Secure it to the mast
section stanchion with the proper screw and lock-nut (take up any slack between the screw head
and the ring nut itself). The connection, instead, prevents M48 nut from screwing out and falling
down (picture 2.2.14).

Picture 2.2.14

2.2.4.7 Tensioning order for the bolts connecting tower sections, anchor plates, undercarriage
and TS21 lower slewing ring support.

8 £ £ 1 4 £ £ 5

Picture 2.2.15

6 £ £ 3 2 £ £ 7

4B_TS12_000_e TS12 Tower Erection Page 20/23

2.2.5 Final checks

Loosening is an inherent risk of the bolt connection even if secured with the special lock ring, screw
and lock nut called for in picture 2.2.14.
Therefore, visually inspect bolts for proper tightening within 3 weeks from the initial erection.

F Bolts that loosen shall be removed, cleaned and greased again prior to their retightening.
The operation is crucial, since the tower section stanchion remains temporarily with only one bolt
in place (instead of two).
Therefore remove one bolt at a time, moving the counterjib of the unloaded crane to the same side
of the connection being removed, thus avoiding possible tensile stresses on the stanchion.
The operation shall not be carried out, anyhow, with wind blowing hard.
Check bolts for loosening with the same tools used for tightening.

F Further controls shall be performed at quarterly intervals by the operator or other

designated person.
These control cannot exclude, however, the risk of accidental loosenings or breakage of the
components. A regular inspection (even a visual one) shall certainly allow to detect possible slacks
between the bolts and the connection.

F Visible cracks (even slight ones) on the bolts are reasons for immediate replacement.

Perform controls on the bolts and bolt retightenings with the crane properly balanced (vertical load
active and no moment affecting the tower).

Page 21/23 TS12 Tower Erection 4B_TS12_000_e

 3 DISMANTLING
3.1 REQUIREMENTS FOR DISMANTLING

A) Establish an area inside the job site in which all the components of the tower shall be stored.
It is advisable to keep all the parts off the ground.
B) Verify that the tower is still structurally sound to carry out the disassembly in a safe manner.
C) Ensure that there are no electric cables, overhead or ground systems which could interfere
with the disassembly maneuvers.
D) The person responsible for the job site shall check that there are no people within the crane
disassembly area.
Put barriers where feasible.
E) Check that the hoisting devices supplied by the Customer meet the job specific criteria.
The appropriate mobile crane for the crane tower erection shall be chosen according to:
ð the crane installation type (“R” - “F” - “FP” - “T”)
ð the tower height
ð the crane model (slewing upper part)

F For a correct choice refer, therefore, to Chapters 4A “Tower - Dimensions &

Weights” and 5A “Slewing Upper Part - Dimensions & Weights” of the crane
operation manual, as well as to the recommended assembly procedure illustrated in the previous
pages.
The erector shall inspect the conditions of the ropes, chains and slings which are to be used
for hoisting the crane components.
The erector shall inform the mobile crane operator of the exact weight of the parts
that are to be hoisted.
The mobile crane operator is fully responsible, instead, for the slinging and hoisting
of the loads.
F) During the slinging phases, before removing the bolt-connections of the various crane
components, verify that the center of gravity of the part to be lifted and the attaching point of the
cable coincide.

3.2 DISMANTLING THE TOWER

A) Sling the top tower section.

B) Remove the connecting bolts.
C) Lower the top tower section to the ground and place it in a horizontal position.
D) Proceed according to the same disassembly sequence for the remaining tower sections.
E) Remove the electrical box support frame and the electrical box from the base mast section.

4B_TS12_000_e TS12 Tower Erection Page 22/23

3.3 DISMANTLING THE UNDERCARRIAGE

A) Remove all the ballast from the undercarriage.

B) remove screws connecting the undercarriage to the screw jacks or the nuts connecting it to
the subundercarriage ballast blocks;
C) sling the undercarriage, hoist it and lower it to the ground;

- Undercarriage C32
D) disconnect “B” beam from “A” beam as shown at para. 2.1.1 but in the reverse order.

- Undercarriage C38

F Information not available.

Consult Comedil’s Technical Department.

3.4 CRANE STORAGE

Properly grease all the mounting holes and bolts.

Protect the unpainted parts (close to the bolt-connections).
Protect all the electrical parts (motors included) against bad weather conditions by covering them
with rainproof sheets.

Page 23/23 TS12 Tower Erection 4B_TS12_000_e