Old and new Written by Kessel - 01 Mar 2008 Extra crane capacity, especially in the top slewing tower crane sector, is in strong demand worldwide. Product innovation is another busy area, notably the “trendy innovations• of flat top and luffing jib models, delivered by the well known international leaders, including Comansa, Jaso, Liebherr, Potain, Terex Comedil and Wolff. New manufacturers are entering the international scene, mainly from the east, for example, a number of Chinese companies. Nationally established companies are now also looking for export opportunities. Cranes from these manufacturers are not only found in the market hot spots of, for example, the booming Middle East market. The former Soviet socialist countries are also rapidly becoming a ready market for reliable imported cranes. Wilbert’s WT325L in the foreground working alongside one Wolff 180B, Wolff 160B and Wolff 320B in the German city of Frankfurt. To increase free-standing height Wilbert uses its new containerised 2.4 x 2.4 x 6.64 m TC24 tower system as a base tower. This is claimed to be even stronger than the Wolff TV25 system There are many upcoming large scale projects, for example, numerous new power stations to be built in Europe and North America, plus other large infrastructure projects under development. These are precipitating a shortage of high-lifting and special application tower cranes. The renovated Peiner SN500 from Kaufmann Kranservice GmbH ready for work in its second life It is little wonder then that veteran giant tower cranes are back at work. Durable steel structures mean that essential refurbishment work on these cranes from the 1970s is limited to fresh paint and new wire ropes. In some cases an update of the drives and controls, accompanied by a sophisticated redesign of the rigging facilities, will make the crane comparable to newer designs. Above all, a reasonable price and a short delivery time are strong arguments for such reanimations of these crane dinosaurs. An example is the Peiner SN500 and SN630 designed in the early 1980s. They are from the early SN range, used for the construction of the famous Hong Kong Shanghai Bank building. Switzerland-based tower crane rental specialist Kaufmann Kranservice GmbH refurbished one SN500 and replaced the conventional Ward-Leonard drive for the hoist and derrick winch motions with up-to-date frequency-regulated drives. This almost halved the required power connection from 400 to 220 kVA. Its maximum capacity of 32 tonnes to 17 m radius means the luffer finds a ready market on industrial and infrastructure projects on the national market.
Due to the unexpected rise in demand for luffing jib cranes in Germany, tower crane manufacturing and rental company Wilbert has also opted for a luffing jib veteran. This crane, however, was redesigned to cope with today’s market conditions. The original upper crane was the diesel-hydraulic Wolff prototype of the later Hydro Wolff generation, manufactured in 1984. Following extensive use as a harbour and yard crane, Wilbert bought the upper crane in 2007 and transformed it into the WT325L e.tronic. The crane design was radically updated in a few weeks, before the crane was rigged on its first construction job in the German city of Frankfurt. The machinery platform was completely rebuilt and shortened. It was modified to take standard Wilbert concrete ballast instead of the former steel ballast. In addition, all drives were replaced with electric frequency-regulated types as German contractors are unfamiliar with diesel tower cranes. Rope pendants were replaced with erection-friendly tie-bars and the old cab was replaced with the standard Wilbert ergonomic cabin. The WT325L e.tronic is working as a competitive partner to the Wolff 320B on the city site. It will remain, however, a unique unit in the Wilbert rental fleet because Franz Rudolf Wilbert has produced its own versatile luffing jib crane design in the form of the WT205L presented at the 2007 Bauma show in Germany. Two units of this revolutionary transport-friendly luffer are working and a third is in production. Wilbert has plans to expand its luffing jib model range in the upper capacity class. Finding a solution In Liege, Belgium, rental specialist Neremat NV won the contract to deliver two Potain MD 900 cranes. Their 70 m radius was to serve the prestigious new Euro Liege TGV station roof that is 10,000 tonnes of elegant steel structure. While on the city site the arches were prefabricated with the assistance of two Liebherr 420 EC-H cranes before being slid over the station platforms. Access to the hilly construction site was limited, meaning that two high capacity tower cranes with long booms were needed. Due to the short delivery time requested by the construction company, Potain was unable to deliver the required large cranes as all-new units in time. Instead Neremat found a Potain MD 900 built in 1988 and an older K8/118, later called Potain MD 1000. De-rigging the Potain MD 1000 at the Liege TGV station using a 500 tonne capacity telescopic boom crane located on a platform cut into the foot of the hill. The MD 900 in the background was responsible for loading waiting trailers with components of the MD 1000 Thanks to their strong steel structures, it was decided to adapt the older cranes to the required site conditions. Both cranes were delivered fully reconditioned and with 60 and 70 m jibs. The MD 900 was fitted with Potain’s new Vision cab. During the project Neremat had to cope with cramped site conditions. The 25 m deep excavation was completed in 2003 when the MD 900 arrived on site. A 650 tonne telescopic mobile crane had to lower a 160 tonne capacity crane into the pit to rig the tower crane. All crane components were also lowered in by the big telescopic crane and then transferred on trailers in the excavation. One of the structural tubes forming the awning of the station roof had to pass right through the 4 x 4 m wide tower of the MD 1000. The corner strut of one mast section was cut during the construction period and a purpose built gate-like edge member was inserted into the tower section to let the tube pass through. De-rigging the cranes in 2007 was also a challenge for Neremat as the cranes were now towering over a parking deck next to a steep hill. To dismantle the tower cranes, which were
up to 78 m tall, with rigging components of up to 31 tonnes, two access platforms for 500 tonne telescopic cranes were cut into the hill. Dismantling took two weeks without climbing operation. Large tower cranes dominate the sky over the Mediacite project, also in Liege. This time it is new Wolff saddle jib cranes from the XXL range, each with 25 tonnes maximum capacity. In addition to three Wolff 8060.25s, two Wolff 6071s were installed just one year after Wolffkran’s Belgian branch office opened. At the time of writing Liebherr had erected two of three new 355 HC-L luffing jib climbing tower cranes serving the tallest skyscraper in the Netherlands. Only luffing jib cranes could cope with the restricted site conditions of the 165 m tall building on the waterfront at Rotterdam. In addition to level luffing to give a horizontal load path and frequency drive units, erection weights can be easily adapted to specific site conditions. Maximum weight can be kept under 10 tonnes by lifting the jib in two sections and by disconnecting four bolts connecting the machinery deck to the slewing platform and by removing the hoist and luffing gears. Concrete ballast can be chosen as an alternative to fixed steel ballast. The two versions of the crane are 32 or 24 tonnes maximum capacity on two falls of rope. Straightforward reeving of the hook from single to double operation by inserting a pin is to allow quick adaptation to site conditions. Fevelle Favco MK-1200 being used to raise the boiler house of a power plant in China. The crane is powered by electrical drives and has main hoist and auxiliary winches Out of Europe While in Europe frequency drive helps reduce power consumption, Japanese tower crane manufacturer Ogawa has a different approach. Working with general contractor Takenaka Corporation Ogawa put into service the first prototype of a so-called Hybrid Tower Crane. Energy savings around 7% are claimed. The OTS-60NE luffing jib climbing tower crane has 8 tonnes capacity and picks 1 tonne at 30 m radius. It is suitable for small to medium sized construction projects. The revolutionary power saving accumulator control system on the Ogawa crane uses power from a rechargeable battery, acting as counterweight, mounted on the machinery platform. This is combined with an electric double-layer capacitor and mains site power to help cut construction site carbon dioxide emissions. Both power sources are used together when hoisting loads that need a large amount of power. When lowering loads, however, power generated in the hoist is charged back to the battery. Peak power consumption is also reduced. It can be installed as an alternative to diesel driven mobile cranes in low-voltage regions. Ogawa’s OTS-60NE hybrid tower crane with the accumulator system on the back of the counter jib For a 99 MW power generation construction project in China, Favelle Favco delivered two MK-1200 luffers, a 2,500 tonne-metre class crane, with electric drive instead of the traditional diesel hydraulic drive. Capacity is 140 tonnes to 17.5 m radius, while at 40 m radius the 100 kW electric motor will still lift 50 tonnes. Just two ties were needed to achieve the 132 m final tower height. The MK Series delivers the load capacity of the Favelle Favco M-series using KrØll winch technology. Marr Contracting Pty Ltd in Australia is again using its massive Favelle Favco M1680D for a heavy lift job. Capacity is 200 tonnes at 15 m radius in four fall operation. For the first time the M1680D is rigged on a travelling base to build an iron ore load out jetty at
Cape Lambert in Western Australia. It will move along the 260 m high structure and lift modules weighing as much as 125 tonnes. World record luffer Simon Marr forecasts a bright future for high capacity luffing jib tower cranes and ordered what he claims is the biggest luffing jib tower crane ever built. This giant, again manufactured as a tailor made machine by Favelle Favco, will be called M2480D. At the time of writing in early 2008 this diesel hydraulic luffing jib climbing crane was on track to meet its delivery schedule. The new crane offers around double the capacity of the well-known Favco M1280D. It will be able to free stand on an 80 m tower and is designed to be transport-friendly as components are within 4 x 4 m square. Maximum boom length will be an incredible 90 m. According to Simon Marr capacity of the M2480D will be a respectable 275 tonnes at 15 m radius and 9 tonnes at 90 m. KrĂ˜ll K-1400s climbed using an external climbing cage The largest saddle jib crane so far from HanKook Tower Crane is the 2080HC. It offers 20 tonnes maximum capacity in four fall operation and 12 tonnes in two fall mode Two HanKook HKL1250 luffing jib cranes reveal their relationship with Liebherr in terms of several design features Stateside Turning to the US tower crane market, the expected synergy effects of the Potain takeover by Manitowoc are manifest in the growing fleet of large Potain cranes there. It can be seen that rental houses with experience of Manitowoc mobile cranes opt for Potain tower cranes when branching out into the tower crane rental market. Potain adapts the product line to specific customer needs. In the US these are different from most European countries. Due to high-rise inner city projects, for example, and reservations about frequency controlled winches, high capacity Potain luffing jib cranes, which have their design roots in the BKT luffing jib range, are very popular. Their swinging ballast system means that corner forces are moderate. Even though the crane has a maximum capacity of 24 or 32 tonnes, an economic and lightweight standard 2.45 x 2.45 m K850 and K839 tower system can be used. LJ Companies is one of the fast growing rental companies adding Potain tower cranes alongside its heavy haulage and mobile crane fleet. The first tower cranes were bought in 2006. Paul Fioravanti, vice president, explains that LJ now operates more than 15 Potain tower cranes, including MR 405B, MR 605B and MR 615B luffers, plus MD 485 saddle jib cranes. To cope with taller buildings, where electric tower cranes are used today, and with the increase in load; Potain has developed one- or two-fall versions plus the classic two- or fourfall version in the 400 and 600 tonne-metre class. One of three STT293s from Jin Long Europe on an East London project. It is rising in selfclimbing mode to a final height of 168 m Preparing the climbing frame and hydraulics on one of London Tower Crane’s three new STT293s from Jin Long Europe
In contrast to, for example, the SN605, 41 units of which have been built, the new SN615, of which three cranes have already been manufactured, the maximum load of 32 tonnes is lifted in two-fall operation mode instead of on four falls of rope. Preparing the climbing frame and hydraulics on one of London Tower Crane’s three new STT293s from Jin Long Europe Further afield Denmark-based KrØll is known for high capacity custom-built cranes. It delivered four K1400 tower cranes for pre cast erection work at the huge casino project in Macao. To handle the 20 to 28 tonne heavy concrete beams on the 250 x 310 m footprint of the East Podium two cranes were rail mounted. Their 15 x15 m undercarriage moved on rails over beams spanning 20 m between pile caps. With 100 tonne jacks the bogie groups had to be turned 90 degrees to enable work on a perpendicular crane track in the development of the project. Both cranes were travelling with full load. A load of 24 tonnes could be lifted at 60 m radius while the maximum capacity of 30 tonnes was available up to 49.8 m radius. By adding a second trolley and a new hook block maximum capacity could be increased to 60 tonnes. The K-1400s were based on a 3.6 x 3.6 m M40 mast section. The panels are made up of diagonals and column members can be folded together to reduce transport volume. On that project free standing height was restricted to about 60 m. Depending on the required wind speeds in out of service condition, up to 90 m or even more can be achieved. The current construction boom has been so explosive that construction and rental companies have scrambled to get their hands on whatever machine they can to reduce delivery time. At the same time there is a second trend to decrease investment by opting for less expensive cranes. These are not units built by the traditional European market leaders but it no longer necessarily means poor quality. Far Eastern manufacturers that have established themselves on their home market are penetrating the world market. An example is HanKook Tower Cranes of South Korea. Tower crane production started in 1978 and a sales organisation was set up in Dubai in 2007. HanKook claims to have the largest market share in South Korea. Thanks to a licence agreement with Liebherr in 2003 more enhanced products and optimisation of the production line were achieved. The saddle jib cranes’ design is rooted in the classic Liebherr HC range. Since 2005 HKTC has set new standards with its luffing jib models and 2080HC. The tower system and some design features still show a relationship with Liebherr products. The newest addition, the 2080HC, enters the capacity class of the Liebherr 550 EC-H (20 tonne version). It has the same maximum jib length of 81.5 m and tip load of 4 tonnes. It also uses a 2.45 x 2.45 x 5.8 m tower system. HKTC, however, supplies a side mounted cabin that reduces the maximum erection weight compared with the Liebherr. The HKTC luffing jib tower cranes, 1855HKTC and 1250HKTC, offer 12 and 18 tonnes maximum capacity. The Elmag drive units and the 2.3 x 2.3 x 4.14 m tower sections are well known from classic Liebherr tower cranes. The machinery platform is bolted on top of the slewing unit, which helps to reduce component weight during erection. HKTC luffers are already working in the booming Middle East. Fellow Korean manufacturer Hanwoo TNC, now represented under the new trade name Everdigm, started tower crane fabrication in 2002, relying visually on KrØll and Raimondi design features. Standard features include: inverter control for all movements; remote hook fall change; stainless steel panel cases; and the selection of a normal or level luffing junction on the cabin touch screen of luffing jib cranes.
A number of Everdigm (Hanwoo) tower cranes like this KH310 in the foreground and the KH420 cranes in the background are working on shipyards with static undercarriages which can be moved around by self propelled units These follow the KrØll design and are examples of the high standard specification of Everdigm tower cranes. Everdigm offers two luffers; the 16 tonne capacity KH200L and the 8 tonne KH100L. The saddle jib crane range is the KH420 with 16 tonnes capacity and the 14 tonne KH310. Chinese tower crane manufacturer Yongmao has further strengthened its position in Europe by delivering the first STL230A luffing jib cranes to UK rental house London Tower Crane Hire & Sales Ltd, via European distributor Jin Long Europe. London Tower Crane has bought a further 10 units, the first of which has just been delivered to the yard in Peterborough, and will be erected on site shortly in London. The STL230A can free stand to 78 m, lift a maximum of 18 tonnes and can lift 2 tonnes at 55 m jib end. The large number of power station construction projects under way means that both the heavy lift sector and the top slewing tower crane market are booming at the moment. Pictured left is a typical boiler house construction site in Germany An Everdigm (Hanwoo) KH200L luffing jib crane. The upper crane shows its relationship with KrØll design features With the STL230A London Tower Crane is closing the gap between Terex Comedil models with fixed ballast and the larger Jost cranes with movable ballast. Until now only Select Plant and HTC were known for climbing tower cranes in the UK. London Tower Crane entered the scene by climbing the STT293 flat top cranes. These are on the latest high-rise tower built in London’s Docklands. Final height of one of the cranes will be 168 m using three anchorages to the building (see News). Paddy Donaghy, sales manager, and a major driving force in the continuing growth of London Tower Crane Hire & Sales, is now looking at the heavier crane market. “The tower crane provided by Jin Long Europe has proved itself over the last eighteen months and our clients are all very satisfied with the reliability, and we are now ordering the STT403 and the STT553.” The STT553 lifts 24 tonnes out to 24 m radius and the maximum at 80 m jibend is 4 tonnes. Maximum free standing height is 86 m and it can be climbed to 235 m. Donaghy said, “Over the next year we will increase our fleet of Jin Long tower cranes.”