THE DEDICATED RESOURCE FOR THE CRANE INDUSTRY / MARCH/APRIL 2019
AUSTRALIAN FIRST Cosmo Cranes’ new Demag all terrain cranes.
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IN THIS ISSUE 25
52
54
14 New Demags for Cosmo Cosmo Cranes took delivery of two Demag cranes, including the first AC 300-6 to be delivered in Australia. 18 CICA – Industry Report The latest updates from CICA. 26 CICA Life Member: Rob Way Read about the career of Rob Way in the latest in a series of articles focusing on CICA Life Members. 28 From cradle to the crane Nick Bucciarelli talks about his family’s lifelong passion for cranes in this issue’s CICA Member profile. 30 Update to Australian Standard for collared eyebolts and eyenuts Eyebolts and eyenuts are used everyday in the lifting sector and changes to the Australian Standards will impact everyone. 32 Rising to the lifting challenge KITO PWB’s range of chains and lifting gear is manufactured with Australian steel and every chain link tested beyond Australian Standards. 36 Ensuring the crane sector has the right insurance coverage Crane operators need comprehensive insurance to protect themselves and their business, so it’s important to have the right cover. www.cranesandlifting.com.au
40 Service and support the Liebherr way Aftersales support doesn’t just include service and spare parts back up, it can define the culture of the crane supplier and its commitment to supporting the customer. 44 1200t Liebherr brings renewables focus to the MAX The largest telescopic crane in the southern hemisphere is being put to work in the renewable energy sector. 46 Where to now Humma? Cranes and Lifting Magazine gets an inside look at the Humma range of pick and carry cranes. 50 Understanding 3D lift planning Cranes and Lifting Magazine spoke to A1A Software LLC President Tawnia Weiss about the company’s history and plans for the Australian market. 52 Manitowoc Potain and The Manitowoc way Details of Manitowoc’s new model Potain tower cranes and just how well they’ve been embraced by the Australian sector.
54 Tadano brings new models to the market Tadano has recently added new models to its telescopic crawler and 3 axle all terrain ranges. 56 Keeping Pace with maintenance and support With the opening of a new facility, Pace Cranes is building on its success as a servicing and repairs specialist for over 30 years. 58 Big data boosts crane safety Robway Safety is using data collection technology to improve operator behaviour and awareness. 60 New KATO Cities to Borger Cranes Borger Cranes took delivery of a new 20t KATO City Cranes, thanks to the reliability and performance of other KATO models in the Borger fleet. 62 Ensuring the hook and rigging interface is correct Stuart Edwards from Edwards Heavy Lift continues to look at the hook of the crane and other rigging component interfaces. Official Media Partner ph: 03 9501 0078 e: admin@cica.com.au March 2019 CAL / 3
FROM THE EDITORIAL TEAM Published by:
COMBINING TECHNOLOGY WITH TRADITIONAL BUSINESS VALUES WELCOME TO THE March/April issue of Cranes and Lifting Magazine. In many ways, it is a privilege to immerse in and report on the different dynamics within the crane sector. It’s interesting to see manufacturers designing and engineering new models that lift heavier weights, higher and over greater radii and crane operators continually adding to their fleets to cater for changing customer demands. Behind the scenes, CICA continues to lobby and cut through government red tape to make life easier for crane operators. In this issue, we cover a number of new models, including the largest telescopic crane in the Southern Hemisphere. It will be interesting to see how these perform in the field. In my experience, many industry dealings are based on traditional values such as relationships, trust, and backing the customer day and night. As a manufacturer, providing a new piece of equipment is only one step in a business relationship and if the back-up and support isn’t part of that relationship, it isn’t going to last long. Insuring your business against the
expected and unexpected can be costly, but it can be devastating if you don’t have the right level of cover. This issue includes an insight from one of Sydney’s largest crane hire businesses and its insurer (page 36). The CICA Life Member profile is all about safety. Rob Way was a pioneer in crane safety and today his name is still synonymous with advanced crane safety systems. You can read about Rob on page 26. In Victoria, it’s great to see CICA, the CFMEU and crane specialists working together on a trainee program. The ability to do so is the first step in addressing an industry-wide issue where a large proportion of crane operators, dogging and rigging license holders will retire in the next 10-15 years. As always, on behalf of the Cranes and Lifting Magazine team we hope you enjoy the read and if you think you have a story to tell, you probably do, so please make contact.
11-15 Buckhurst St South Melbourne VIC 3205 T: 03 9690 8766 www.primecreativemedia.com.au Managing Director John Murphy John.Murphy@primecreative.com.au Chief Operating Officer Brad Buchanan Brad.Buchan@primecreative.com.au Publisher Christine Clancy E: christine.clancy@primecreative.com.au Managing Editor Robbie Parkes E: robbie.parkes@primecreative.com.au Editor Simon Gould E: simon.gould@primecreative.com.au Journalist William Arnott E: william.arnott@primecreative.com.au Business Development Manager Nick Markessinis E: nick.markessinis@primecreative.com.au T: 0422 800 920 Client Success Manager Justine Nardone E: justine.nardone@primecreative.com.au Design Production Manager Michelle Weston E: michelle.weston@primecreative.com.au
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RETHINK INNOVATION
Change the way you look at efficiency
Your cranes need to be easy and efficient to transport, set-up and handle. That’s why since bauma 2016, we’ve reignited our innovation engine and launched 10 new cranes and innovative new features like asymmetric outrigger positioning and boom booster, adding to our over 500 patents. These are just a few of the many ways we’re adding efficiency to your fleet and increasing your bottom line through innovation. And we’re not stopping there. Come and see how we’re continuing to rethink innovation at Bauma 2019.
© Terex Cranes 2019. Terex and Demag are trademarks of or licensed by Terex Corporation or its subsidiaries.
INDUSTRY NEWS CRANES BEGIN HEAVY LIFTING FOR NEW M1 BRIDGE More than 3400 tonnes of precast concrete will be lifted into place as part of the $2.3 billion M1 upgrade project in Queensland. Night time diversion was put into place along a 5.5 kilometre stretch of the M1 to allow cranes to lift 52 concrete girders and begin work on a new fourlane bridge over the M1 at Underwood. Queensland Minister for Transport and Main Roads Mark Bailey said the Underwood Road Bridge demonstrated the State Government’s commitment to build a better M1 between Brisbane and the Gold Coast. “The heavy lifting of the first bridge girder is concrete evidence of our commitment to reduce travel times for motorists,” Bailey said. “Moving the new bridge’s 52 girders, each weighing 65 tonnes, into place isn’t a small task. “It requires precision and expert engineering to get the job done and ensure motorists spend more time with family doing the things they enjoy, sooner.” Federal Cities, Urban Infrastructure and Population Minister Alan Tudge said the new bridge was a significant milestone for the $195.3 million M1/
Construction has ramped up on the Underwood Rd bridge.
M3/Gateway merge upgrade. “Major construction on the new Underwood Road bridge – which only started in September last year – will bust congestion and get motorists home sooner and safer,” Tudge said. “I have travelled around the area, and have seen the M1/M3/Gateway merge project continue to progress it will be a huge benefit for south east Queensland motorists.” Federal Member for Forder Bert van Manen said works for this crucial stage had been designed to minimise disruption to motorists during peak times with the hoisting of the precast girders at night. “Seeing large girders in the air signals we’re making good progress on our goal to open the new, four-lane Underwood bridge to traffic late this year,” van Manen said. “I want to thank motorists for their patience while this important upgrade
CRANES ASSIST SYDNEY METRO OVERNIGHT ENGINEERING OPERATION A large-scale engineering operation in the heart of Sydney has helped to keep pedestrians flowing while the new metro station at Martin Place is built. A block of Martin Place was excavated around 10 metres from street level and two level pre-fabricated steel pedestrian bridge
Two cranes were used in the operation at Martin Place.
6 / CAL March 2019
is underway and remind drivers to be aware of changes to road conditions.” Member for Springwood Mick de Brenni said the first girder lift would be a welcome sight for the local community. “Our community is feeling a lot of relief seeing the next big step in the M1 upgrade being delivered. Moving the new bridge’s 52 girders into place isn’t just a construction task, it marks a turning point in our local history where we can see the light at the end of the congestion tunnel,” de Brenni said. “The bridge widening follows the upgrade of the Underwood Road and School Road intersection and signals an exciting future for local bus commuters and motorists alike.” The Federal Government has contributed $115 million alongside the Queensland Government’s contribution of $80.3 million for the jointly funded infrastructure project.
were lifted into place in a nighttime operation. The bridge allows commuters to access Martin Place at both the surface and subway levels while the southern entrance of the station is being excavated. This means a section of Martin Place between Elizabeth and Castlereagh streets can remain open. Most of the section of Martin Place between Castlereagh and Elizabeth streets was excavated to prepare for the installation of the bridge, including a one metres thick concrete slab. Two cranes lowered a double storey 45 metre walkway into place in three 15 metre pieces on the last weekend of 2018. One section was lifted into position from Elizabeth Street and the remaining sections were installed from Castlereagh Street. Pre-existing sub surface infrastructure, including old brick tunnels, pedestrian underpasses and utilities were not affected by the works. The temporary bridge will be in place until overstation development is underway in 2022. Roadheader tunnelling machines are excavating the underground station and have removed more than 110,000 tonnes of rock so far. www.cranesandlifting.com.au
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WE’RE WORKING TODAY,tOSHAPE TOMORROW HITACHI SUMITOMO CRANES.
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IN AUSTRALIA 1938-2018
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INDUSTRY NEWS
The crane was originally built in 1948 by Malcolm Moore Limited.
HISTORIC MELBOURNE CRANE RETURNED TO FORMER GLORY Melbourne’s last original electric crane has been restored to its former glory as part of a project that aims to revitalise the northern banks of Melbourne’s Yarra River. The Malcolm Moore Crane had originally been built in 1948 by Malcolm Moore Limited, and is part of the most intact cargo berth in the port of Melbourne from the precontainerisation era. It was recognised for its historical significance to Victoria in 2002. The crane will be restored as part of as part of private developer Riverlee’s $450 million mixed-use development, in collaboration with Lovell Chen Architects and Heritage Consultants, the City of Melbourne, Department of Planning, Department of Treasury and Finance, and Heritage Victoria. It was originally located on the west end of the historic Goods Shed No. 5, however it has been relocated and restored to the east end to make it more publicly accessible, and to integrate it with a proposed public park. The crane has been restored to ensure its structural integrity through a collaboration between Maritime Contractor Freyssinet and Lovell Chen. The wharf dates back to the immediate post-war era and has also undergone significant refurbishment. Riverlee’s Development Director David Lee said the crane demonstrates what a lively area the wharf once was in the mid 1900s. “We are excited to bring the rich history of the site back to life as much as possible and in particular, the restoration of the crane was so important to both Riverlee and the various partners involved,” he said. “We look forward to continuing to tell the story of the site’s historical relevance and reference its history throughout our project.” Construction on the multi-use development is expected to begin in the first quarter of 2020, with the crane visible from Seafarers Bridge. www.cranesandlifting.com.au
TEREX CRANES RETURNS TO PROFITABILITY IN 2018 Terex Cranes has released its full-year 2018 results, reporting a net sales of $US1.3 billion (AU$1.82 billion), a 10 per cent increase compared with 2017. The company found its cranes business had made improvements in materials management and operational performance and has returned to profitability in the fourth quarter of 2018. Sales for the Terex Cranes segment grew 12 per cent compared to 2017, reaching $US365 million (AU$510 million). Overall, Terex Corporation reported net sales of $5.1 billion for 2018, an increase of 18 per cent compared with the previous year. The news follows the company’s recent move to sell its Demag Mobile Cranes business and exit mobile crane product lines manufactured at its Oklahoma City facility. Terex will continue to manufacture and support specialised crane products, including its pick and carry cranes in Brisbane, Australia. Terex Cranes President Steve Filipov said in the further quarter of the year, the Cranes segment succeeded in overcoming the material supply challenges which had impacted its performance earlier in 2018. “The sale of the Demag Mobile Cranes business to Tadano Ltd is based on strong industrial logic,” Filipov said. “Bringing these two complementary businesses together will combine Tadano’s 100 years of experience with Demag Mobile Cranes’ nearly two centuries to create a lifting company capable of bringing new leadership to the industry and continuing to create innovative lifting solutions. Terex Chairman and CEO John Garrison said the global team had executed well in the fourth quarter, completing a strong year for Terex. “We will continue to support all of our customers, including those affected by the changes in our Cranes segment, as we execute our strategy to be a high performing, customer-focused company,” he said. Terex has released its full-year 2018 results.
March 2019 CAL / 9
KHL’S INTERNATIONAL ROUND-UP
AROUND THE WORLD WITH KHL Cranes and Lifting has partnered with supplier of international construction information KHL to bring you news from around the world. TEREX SELLS DEMAG TO TADANO Terex Corporation has agreed to sell its Demag mobile cranes business to Tadano for approximately US$215 million. The deal, which is subject to regulatory approvals, covers all terrain cranes and large crawler cranes and includes the factory in Zweibrücken, Germany, as well as multiple sales and service locations. The sale is targeted to close in mid-2019. As well as selling Demag, Terex will cease the production of mobile cranes in North America (made in Oklahoma City). However, it will continue to manufacture rough terrain cranes for the global market in Crespellano, Italy, and Terex tower cranes in Fontanafredda, Italy. The Terex pick and carry cranes made in Brisbane, Australia, will also be continued. “The Demag Mobile Cranes business has been part of our company for almost two decades and produces world class products,” said John Garrison, Terex chairman and CEO. “The dedicated Demag Mobile Cranes team members have made significant contributions to Terex and to the crane industry. “The sale is based on strong industrial logic, as the Demag Mobile Cranes business will become part of a global crane company with complementary products and capabilities. We are pleased to have entered into this agreement with Tadano, a strategic buyer who values the Demag Mobile Cranes brand, technology, distribution network and team members.” Koichi Tadano, Tadano representative director, president and CEO, said it was a strategic acquisition with considerable scope for growth, “The addition of the well-respected Demag brand of all terrain cranes and large crawler cranes range extends our product lines and options for customers. “The addition of the Demag branded mobile crane product lines will enhance our global position in this segment. We believe that the Zweibrücken facilities and its global team members, as well as the current distribution partners, are valuable to the future success of the business.” The changes do not affect the Terex Utilities business, which will continue to be manufactured at its Watertown, South Dakota facilities in the USA. Terex’s Oklahoma City plant will continue to produce telehandlers and re-manufactured units for its aerial work platform business as well as various products for its Materials Processing segment. “Although we are exiting the OKC-based mobile cranes products, we will continue to sell parts, and offer service and support to our customers,” said Garrison. He added that during the transition Terex was “committed to providing exceptional service to all of our global customers, including those affected by Terex has sold its Demag cranes business. these changes.” 10 / CAL March 2019
The Potain MD 689 M40 in action.
POTAIN TOWERS OVER A DOME A Potain MD 689 M40 top slewing conventional tower crane helped construct the BioDome at the ZooParc de Beauval in France. It was installed on the Saint-Aignan-surCher site in March 2018 and was nearing the end of the project at the time of writing in early February. With the glass installed the crane is due to be dismantled. It is the largest model in the MD series and on this job had a 60-metre jib and a capacity of 40 tonnes. The BioDome will have space for 3,000 visitors and house komodo dragons, hippos and manatees. Contractor CMF Groupe chose the MD 689 M40 for its high capacity and durability on long jobs, manufacturer Manitowoc said.
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KHL’S INTERNATIONAL ROUND-UP
PRECISION ACQUIRED BY GTI
DANA ACQUIRES SME GROUP
GTI Transport Solution Inc has acquired Precision Specialized Division Inc in Canada. Precision Specialized is a division of Precision Truck Lines. Woodbridge, Ontario-based PSD is an open-deck and heavy haul transport operator in the province. GTI also operates open-deck, specialized and over-dimensional freight services. All jobs will be retained, according to GTI private equity backer Novacap, which also said GTI plans to invest and expand into new markets. All operations will move to Brantford, Ontario, and the name will change to Precision Specialized Inc (PSI). Commenting on the deal Richard Lafrenière, GTI Chief Executive Officer, said, “The team at Precision Specialized has demonstrated market leading know-how in quality of service and engineering of complex project driven loads. We firmly believe that blending their expertise with the broad footprint of GTI will enable us to drive growth and become the preferred open-deck and heavy haul transportation company in North America.” Ed Bernard, former Precision Specialized Division vice president, will now be Precision Specialized Inc president. Bernard said, “Precision Specialized is proud to be joining forces with GTI to propel our company to the next phase of its growth. A team of seasoned managers will bring valuable expertise and an injection of fresh capital will enable us to better serve our customers across North America. Moving operations 60 miles to Brantford gives us much needed space for our growing equipment assets.” Frédérick Perrault, Novacap senior partner, said, “This acquisition is a continuation of GTI’s strategic plan to expand its current capabilities and geographic reach. Combined with the launch of GTI USA in 2018 and other acquisitions in the pipeline, we are very enthusiastic about the group’s future.”
Vehicle transmission and component company Dana Incorporated in the USA has completed the acquisition of Italian electric motor manufacturer SME Group. Headquartered in Arzignano, SME designs and builds low-voltage AC induction and synchronous motors, inverters, and controls for off-highway vehicles, including material handling, construction and agricultural equipment. SME will strengthen Dana’s capability as vehicle and machinery electrification gathers pace. “Dana’s acquisition of SME enhances our ability to address the electrification and hybridisation needs of our customers, while also increasing the potential for incremental content per vehicle,” said Jim Kamsickas, Dana president and chief executive officer. “SME’s exceptional electric motor and inverter products, which largely support off-highway applications, are highly complementary to the technologies we acquired with TM4 [electric powertrain designer and manufacturer from Canada], which are predominately focused on light- and commercial-vehicle applications,” Kamsickas continued. Christophe Dominiak, Dana chief technology officer, said, “The addition of SME’s low-voltage induction motors rounds out our already robust offering of high-voltage permanent magnet motors and enables us to deliver a complete range of electrified solutions for our customers.” The acquisition will extend its capabilities to applications up to 250 kW. The privately held SME Group employs more than 100 people. In addition to Italy it operates in China, Germany and Canada. Dana said its electrification capabilities will also be further strengthened by the anticipated acquisition of the Switzerland-based Oerlikon Group’s drive systems segment. This was announced in July 2018 for a value of CHF 600 million (US$607 million). Dana expects the transaction to close in the first quarter of 2019.
All jobs will be retained in the acquisition.
Dana has completed its acquisition of SME Group.
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13 / CAL March 2019
UP FRONT / DEMAG
NEW DEMAGS FOR COSMO Cosmo Cranes recently took delivery of two Demag cranes, including the first AC 300-6 to be delivered in Australia.
John Handley, Director of Cosmo Cranes. 14 / CAL March 2019
COSMO CRANES IS ONE of Sydney’s leading tower crane hire companies. It boasts a modern range of technologically advanced tower, mobile and franna cranes for hire. The Cosmo Cranes team is well versed with all aspects of crane operations including maintenance and repairs to full-scale construction projects. It recently took delivery of a new six-axle Demag AC 300-6 all-terrain crane, boasting a 300t classification, features an 80m main boom and is the first crane of its size in the Demag range equipped with a luffing jib. This new 6-axle Demag all terrain crane delivers strength, reach and versatility needed for accomplishing the most demanding jobs at lower operational and transporting costs than similar models in its class. According to John Handley, Director at Cosmo Cranes, the new cranes will fit nicely into the company’s fleet. “We’ve been operating frannas for
years but these are the first Demags we’ve owned. We actually ordered the AC 300-6 when we first heard about it, but it was still in the final design stages. We’ll predominantly be using it for the installation and dismantle of our tower cranes. We chose the 300 because it has the biggest long boom in its class,” he said. The AC 300-6 combines long reach with a strong load chart to give operators the perfect fit for efficient work at height or on reach. The 80m main boom can perform jobs at heights up to 78m or 74m radius without rigging a jib. It is ideal for tower crane erection, with a class leading lifting capacity of 15 t on fully telescoped 80 m main boom. Also, the Demag AC 300-6 is the smallest in the Demag range that can be outfitted with a luffing jib for superior reach and fly-over capabilities, bringing the maximum system length to 118m. The well proven luffing jib rigging system is the same as on the AC 350-6 and AC 1000-9 cranes and The AC300-6 80 boom performs at heights up to 78m or 74m radius without rigging a jib.
March 2019 CAL / 15
UP FRONT / DEMAG The new Demag AC130-5 in action.
provides safe and quick rigging. Packed with the latest Demag innovations like the IC-1 Plus control system and a single engine concept with an intelligent motor management system, the Demag AC 300-6 enhances productivity to help reduce operating costs. The IC-1 Plus control system provides real time calculation of the lifting capacities and supports operators in safe crane operation. It also allows asymmetric outrigger positioning. This also allows the crane to perform jobs usually reserved for larger machines. The Demag AC 300- 6 is fitted with a single engine, with start and stop function to reduce idle times and total engine hours contributing to the reduction of fuel costs and preserving the crane’s residual value. The compact design of the Demag AC 300-6 all terrain crane features a carrier length of 15.3m and a width of 3m. The crane is easy to position on the job site, thanks to its active all-wheel steering that allows excellent manoeuvrability in tight spaces. On the road, the Demag AC 3006 crane meets axle load limits from below 12t up to 16t and can travel up to 85km/h. It also has 800kg of extra payload capacity for carrying extra lifting accessories. It includes an axle load monitor, displayed on the dashboard, to help customers drive within the road-legal weight. This model, like all Demag cranes in this product family, can be configured to comply with the variable axle weight limits in most states by connecting different types of boom dollies or removing the boom. “With a mobile fleet consisting of 16, 20 and 25t frannas, the Demag AC130-5 and AC300-6 are a perfect addition, giving us more versatility and independence. The guys at Terex Cranes understand our needs and our business and can provide tailored solutions when and where necessary.” 16 / CAL March 2019
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CICA INDUSTRY REPORT
The changes are expected to make a big difference to operators.
GREATER MOBILITY FOR MOBILE CRANES ON NSW ROAD NETWORK Cutting red tape will enable more access to the road network for the crane industry following the decision to improve access for mobile cranes. THIS FEBRUARY, Minister for Roads, Maritime and Freight, Melinda Pavey said the NSW Government had been working with industry to improve access for mobile cranes to deliver increased efficiency for the construction sector, while maintaining road safety and minimising travel time impacts to the broader community. “I am pleased our work has resulted in two key access improvements for mobile cranes; the establishment of a 60 tonne mobile crane network, as well as extended and more consistent nighttime travel options from 15 February 2019,” Pavey said. Key Points · Roads and Maritime Services (RMS) has worked in partnership with The Crane Industry Council of Australia (CICA) and the National Heavy Vehicle Regulator · These cranes now have easier access to key construction zones when travelling on the state road network to the Parramatta, Liverpool and Chatswood CBDs, utilising the M2, M5, M7 and M4 between Mamre Road, St Marys and Silverwater Road, Silverwater · Mobile cranes up to 15.5m long now have increased flexibility in their travel 20 / CAL March 2019
times with travel now being available from sunset to sunrise · Mobile crane and dolly combinations in excess of 15.5m will also have increased flexibility to travel at night time, subject to conditions including travel outside of clearway times, peak times, or other restrictions in place on specific roads. “This announcement builds on the previous work done to enable 50 tonne mobile cranes greater access to the state road network and demonstrates the NSW Government’s commitment to cutting red tape,” Pavey said. The announcements were made at a formal dinner attended by the minister. According to Damien Hense, Road Safety Liaison Officer with CICA, these outcomes will make a huge difference to crane operators. “We see this as a break through moment as it allows for different types of crane configurations to be purchased in NSW. It also allows crane owners, with cranes within the affected dimensions, to be able to run their cranes without the detrimental impact of a curfew. It means they can run the cranes effectively from sunset to sunrise,” Hense said. Previously, if the crane was over 14.5m
long, operators were required to stop travelling between sunset and midnight, which would effectively mean the crane would be parked, left over night and collected the next day. “Owners now have the flexibility to operate throughout the night time period. This has also resulted in concessions to cranes and dollies which is good news for operators with the larger machines,” Hense said. “The development of the 60-tonne network is another major break through. This network was the result of the hard work by CICA members in NSW, led by Danny Adair. Throughout last year, we initiated the bridge testing system in collaboration with the RMS and that resulted in the lifting of restrictions on 185 bridges across the NSW network. “We developed a road network to link those bridges to enable crane owners to run at 12 tonne per axle on a five-axle machine. This allows the crane to run on and over the 60-tonne network and at the manufacturer’s specification. “Previously, owners had to remove parts from the crane to achieve the desired weight or they had to swing the boom into the dolly. This development now provides dolly free travel on the network, which is also a fantastic outcome.”
Experience the Progress.
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Munich, April 8th –14th Find out more at www.liebherr-bauma.com
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CICA INDUSTRY REPORT
10-YEAR MAJOR INSPECTIONS, A MAJOR EXPENSE – BUT IS THERE A BETTER WAY? The major inspection for cranes is easy to monitor, but if crane owners can demonstrate a willingness to fulfil requirements of a system that bases maintenance on usage, it may be able to eliminate the need for expensive inspections. IT HAS LONG BEEN accepted that 10-year major inspections are the benchmark for crane maintenance. While it is convenient to have a measurable time frame to schedule a major inspection, this method is now under scrutiny. Time-based maintenance (TBM) also called “clock-based” maintenance, or “condition-independent” maintenance is an asset maintenance schedule based on a strict timetable. Light vehicle maintenance is done
based on usage and this is also now being considered as a more effective model for crane maintenance. It stands to reason that usage is a better measure than time, if a crane is utilised every day or if it is used only once a week – the wear and tear will differ considerably. In 2016, the standard for crane design, ISO 4301, was revised to classify cranes based on cycles, not hours. For cranes with low utilisation rates, the ten-year major inspection
Preventative maintenance is based on utilisation. 22 / CAL March 2019
guideline is impractical and introduces premature expense. Banks, government regulators and insurance companies also use the 10-year measure, which complicates the implementation of any other system. CICA CEO Brandon Hitch said that for another system to work, greater self-regulation is required. “In most industries where heavy machinery is used, preventative maintenance is based on utilisation, so a condition monitoring schedule based on manufacturer’s recommendations is best practice. Utilisation is a combination of how often the machine is used and how ‘hard’ the machine is worked.” Ongoing maintenance for cranes means that maintenance issues will be detected earlier, rather than later – it is a more accurate system, but for it to work, there needs to be industry compliance. In line with ISO 9927-1:2013, AS2550.5-2016, AS2550.11-2016, AS2550.1- 2011 and AS2550.10-2006, CICA recommends considering an alternative condition monitoring approach to the existing default practice of conducting a major inspection at 10 years. Responsibilities under workplace legislation can be met in many ways. There is no “one-sizefits all” position in relation to safety issues and workplace safety legislation explicitly allows for this as a way of encouraging safety measure innovation. The following recommendations should be considered: Crane Design Life should be clearly broken into two
types according to AS1418.1-2002[8]: a. Mechanical Components – Design Life of 10 years b. Structural Components – Design Life of 25 years. A combination of condition monitoring and manufacturer’s recommendations are the best approach to maintain a crane. It is critical for crane owners to follow the maintenance regime outlined by the manufacturer and maintain records of crane operation, service, and maintenance. Service and maintenance records throughout the life of the crane should be retained, e.g. photos, maintenance logbooks, service checklists, invoices, etc. These records can assist in detecting the Residual Life of the crane and crane
A combination of condition monitoring and manufacturer’s recommendations are the best approach to maintain a crane. components. Recent advancements in the CraneSafe assessment forms allow for additional record keeping during the CraneSafe inspection by endorsed CraneSafe assessors. This data will empower the crane industry in Australia to move toward a better system. CICA members have access to resources to determine crane load spectrum and winch life which, independent of environmental factors, can be calculated to give crane owners an overview of the winch life and
forecast the remaining design life of the winch based on crane operation hours and the percentage of crane rated capacity used. The 10-year major inspection is easy to monitor which adds to its appeal, but if crane owners and hirers can demonstrate a willingness to fulfil requirements of a system that bases maintenance on usage, then the crane industry by virtue of manufacturer service intervals and record keeping, may just be able to eliminate the need for expensive major inspections.
CICA / TRAINEE PILOT PROGRAM
NEW TRAINEE PROGRAM SET TO ADDRESS FORTHCOMING SKILLS SHORTAGE A major milestone for the crane industry has been reached, as eight Victorian trainees begin their crane journey. EIGHT ENTHUSIASTIC trainees started the new Victorian Trainee Pilot Program in February, ready to start their twoyear journey learning all aspects of the crane industry. This training program is a major achievement and an example of multiple stakeholders in the crane industry working collaboratively. Their ability to do so is a positive response to the dire need the crane industry and construction sector will face as the large proportion of Crane Operator, Dogging and Rigging license holders retire in the next 10 to 15 years. This pilot program is also aimed at combatting the problems associated with existing High-Risk Work Licence courses which are of varying quality, with no minimum course length and minimal oversight. “There is a real concern with the way High-Risk Work Licences are handed out. When people are certified to do such consequential work in three or four days, it is not fair on the student or the company that employs them and dilutes the skills required for the job,” Crane Traineeship Coordinator Andy Chambers said. Over twenty years ago, James Cranes ran a traineeship and the six trainees that were taught and hired by James Cranes are still in high demand in the industry today. Chambers was one of the 24 / CAL March 2019
operators at James Cranes at that time and was part of the team who trained and mentored the six. Today’s trainees will be trained over the next two years, their course involves seventeen core units and two electives, which will be conducted at the CFMEU Education and Training Unit in Port Melbourne, Victoria. “Our desire is that they’ll be competent and armed with a broad skill set that spans all aspects of crane operating, lift planning, business operations and crane scheduling,” Chambers stated. “They will be tomorrow’s leaders and mentors.” All trainees will carry out their practical training with their participating crane companies and log books will ensure that experience in all classifications will be recorded over the two-year training period. The Steering Committee for this project is: Barry Stockdale, P&D Rigging and Crane Hire; Tom Quinlan, Quinlan Cranes; Peter Booth, VIC CFMEU Mobile Cranes; Ralph Edwards, VIC CFMEU Mobile Cranes; and Brandon Hitch, Secretariat, CICA. It was decided by the Steering Committee that a full-time Crane Traineeship Coordinator was needed to see the traineeship begin, succeed and grow. Chambers has over forty years’
experience in the crane industry and brings a wealth of experience to the role. The eight Victorian crane companies participating include: P & D Rigging & Crane Hire, Quinlan Plant Holdings, Metcalf Crane Services, Associated Rigging Australia, Williamstown Crane Hire, Hydralift Cranes, Brent Young Cranes and Rigweld Crane Hire Anne Duggan, the Victorian CFMEU Training Coordinator, and Barry Kearny, Victorian CFMEU Cranes & Rigging Trainer, will be involved in the training components. The trainees will use what they learn at the training centre, to work closely supervised, in one of the nine companies that are part of the pilot program. This is a pilot program, but it is the desire of all involved today, and those who would like to be involved in the future – that this traineeship model paves the way to a sustainable program that can be built on and taught, year after year. ‘The only way is up’ sang Yazz and the Plastic Population back in the late eighties, a song that the James Cranes trainees probably remember. This milestone will hopefully commence an amazing journey for the eight individuals and a lasting model of succession planning that will ensure a safe and progressive industry.
CICA / MY DAD, MY HERO
MY DAD, MY HERO School kids get first hand experience of a mobile crane and what it’s like to be a crane driver. COMMUNITY ENGAGEMENT helps the community understand what crane operators, hirers and owners do. It facilitates stronger relationships and provides the public with balanced and objective information to assist them in understanding more about the crane industry. Earlier this year, Load 28 in South Australia demonstrated community engagement in action. Load 28 was approached by one of their crane drivers, asking if he could do a presentation to school children (including his own) on what dad does and what being a ‘crane driver’ looks like. Load 28 agreed and allocated the crane to visit the school. The children were in awe of the big crane and had a fantastic time as Shaun from Load 28 gave them an interactive experience in crane driving. They found out what a crane driver does, learnt hand signals to demonstrate ‘hook up’ and ‘hook down’ and were able to walk around and see the crane. Shaun and Load 28’s efforts mean that there are now a whole class of kindergarten students wanting to become crane drivers. Here is a firsthand recount of the event. “My daddy came to my school today and told us what his job is because he is a crane driver and he gets to drive very big cranes. Daddy told us today his job was the rigger who has to tell his mate the crane driver what to do. Together they drove his crane to my school and when we all saw it, we went ‘woah, cool!’ because it is so big. My daddy said that cranes can be very dangerous, so we had to be really safe and listen carefully. He told us that he helps build stuff like houses and tower cranes, then he
showed us how his crane works. My class had to help daddy find the right parts on the crane to lift a tyre up. When daddy put the tyre on the hook, all the kids in my class had to use our hands to tell the crane driver to ‘hook up!’. Daddy told us we have to watch closely in case the crane driver fell asleep, and then we all had to yell ‘wake up mister crane driver!’ just like Jeff on the Wiggles, it was so funny. When we wanted to put the tyre down we had to
wave our arms and yell ‘hook down’. My daddy told us if we saw anything unsafe, it was very important to yell “STOP!” and hold up our hand straight. My favourite part was when me and my sister Rose got to touch the hook. We felt so happy that our daddy brought in a crane to school.” It was so much fun and then our teacher (Rob) asked my class who wants to be on a crane crew and everyone in my class put their hand up.”
The children were in awe of the crane Load 28 brought. March 2019 CAL / 25
CICA / LIFE MEMBER PROFILE
LIFE MEMBER ROB WAY This year will see the 40th anniversary of the CICA conference. To help celebrate this landmark event, Cranes and Lifting Magazine is running a series of articles based on interviews with CICA Life Members. IN THE SECOND of the CICA Life Member profiles, we feature Robert Way. Rob has long been regarded as a pioneer of the Australian crane sector and is also recognised as being someone who identified safety and operator training as major issues for the fledgling industry. Ultimately, Rob went on to launch Robway Safety Systems, which still leads the way in crane and safe load monitoring systems today.
Rob Way.
HOW DID YOU GET STARTED IN THE CRANE INDUSTRY? Our business started in 1952 when we were awarded a contract to load and transport tram bogies when trams were being removed from metro Adelaide. To do this we needed to have a 2t crane, so we had a 3t crane made, with a basic boom of 4m and a manual extension of 2m, by a local engineer and mounted onto an ex-Korean War LHD Reo. This led to hiring it out to different people who wanted to lift and shift heavy items, so now we were in a new industry by default as were a lot of the early crane people. HOW DID THE INDUSTRY SEE ITSELF BACK THEN? It was a fledgling industry in the 1950s with 4t mobile cranes being the norm and 2x10t cranes privately made, also being in the mix. There were a few dragline/cranes available and Coles and P&H lattice boom cranes of small capacity available. It was thought, at the time that the lattice boom cranes would eventually be made available in larger capacities. 26 / CAL March 2019
WHAT WOULD HAVE BEEN ONE OF THE MOST DIFFICULT ISSUES TO DEAL WITH? Crane safety has always been an issue to be dealt with. We were restricted mainly to 4t mobile cranes, but customers were wanting to lift heavier loads at greater radii, and this led to overloading and overturning. Lattice boom cranes were more cumbersome and couldn’t lift and carry
a load and needed a truck to move the load consequently customers preferred mobile cranes. We started installing basic load indicators on our cranes and proposed introducing these via the Australian Standards (of which I was a member for 15 years). However, the unions objected to the use of basic load indicators and automatic safe load indicators because they considered that the owners would use them for spying on the operators. Fortunately, now the unions fully support their use. WHAT CHANGES WOULD YOU HAVE MADE IN THE INDUSTRY? None really, everything evolved as the technology changed with the advent of hydraulics. In the late 1950s, crane engineers started using hydraulics to extend and retract single sections of booms and this progressed to multi extension booms which were restricted in length because of the external piping and inadequate seals. This, however, was the start of the evolution of hydraulic cranes. Some of the leaders in the development of hydraulics were our own Con Popov based in Sydney, John Grove, USA, Coles Cranes UK and Liebherr Germany. They had worked out how to return the fluid internally via the extension cylinders with the use of sequencing valves and together with the new designs of telescopic sections, using higher tensile steel. It seemed that the designs and capacities were only restricted by engineers’ imagination. Now we have 1200t telescopic cranes www.cranesandlifting.com.au
“Together with these state associations, it was my pleasure to meet and share ideas with people, not only from around Australia but from around the world.”
Early model weighload safe load indicator manufactured in the UK.
and pick and carry cranes up to 50t capacity. Perhaps I may have started using basic load indicators a bit earlier than I did, and although we trained our own driver/operators to military standards, there still wasn’t enough emphasis put on training Australia wide. Now most of the cranes manufactured in the world have load moment systems installed as standard, so the other part missing in the equation is operator training. One without the other doesn’t equate. WHAT WAS ONE OF YOUR REWARDING ASPECTS OF THE TIME YOU SPENT IN THE INDUSTRY? Meeting other people in the same industry worldwide. This started in 1952 when there was a mobile crane division of the South Australia Road Transport Association made up of a handful of people. This organisation brought together people with problems and ideas to share. This then developed into a more professional state association by using the SA Chamber of Manufacturers for our secretariat. As the industry kept growing, we then established our own secretariat and finally merged with CICA. Together with these state associations, it was my pleasure to meet and share ideas with people, not only from around Australia but from around the world.
After several years trying to get the state associations to agree to an unofficial national conference it finally happened in 1979 at Broadbeach where approximately 150 people attended. This proved a great success and then
following the conference the conference committee met in Perth and it was then that the CICA was conceived. This has proved to be one of the greatest achievements in the history of cranes in Australia. March 2019 CAL / 27
CICA / MEMBER PROFILE
FROM CRADLE TO THE CRANE CICA Member and General Cranes Services Managing Director Nick Bucciarelli speaks to Cranes and Lifting about his family’s lifelong passion for cranes.
The family crane business began in 1989. 28 / CAL March 2019
www.cranesandlifting.com.au
BROTHERS NICK AND ERIC BUCCIARELLI have been around cranes their entire lives. Their grandfather had been a crane owner/operator since the early 1970s, their parents started the family crane business in 1989, and in 2011, the two brothers decided to join the business and diversify the company into what it is today. They established the family owned company General Crane Services WA (GCSWA), which operates throughout the Perth metropolitan area and regional Western Australia. They provide crane, rigging, transport and logistics management for the mining, construction and infrastructure sectors across the state. The Bucciarelli family grew up surrounded by cranes. Each weekend, the two boys would be out with their father, learning and working on them. Nick began his career in 2006, where he found himself working in a fleet control and operations role. He remembers the exact date he was able to operate solo, on 3 September 2007. “The first lift I did on my own was a to lift a pool, but I remember how excited I felt. I had always wanted to be a crane driver, and that was my first opportunity,” Nick Bucciarelli, Managing Director of General Crane Services WA explains. He soon joined the family business in 2007, learning more about the industry and how it operates. In 2011, he would then start GCSWA with just a single 80T Terex Demag and a small team, handpicked for their dedication, passion and expertise within the industry. Now, the company has a fleet of more than 20 cranes, ranging in size from 13T to 250T, with access to larger cranes to service heavy lift projects. Bucciarelli said loyalty is the backbone of his business, not only to its customers, but to its staff and suppliers as well. “We work in a very small industry, so it makes absolute sense to act with integrity and do the best we can for everyone,” he said. “GCSWA has a long-standing relationship with crane manufacturer Terex Australia, with our fleet almost exclusively supplied by Terex Cranes. Terex and Demag have proven to be reliable, versatile and deliver a high
return on investment. “We are also very excited to be the first company to order and soon take delivery of the first Terex 40T pick and carry crane in West Australia. The technological offering of this machine will not only complement our fleet, but also enable us to service a broader range of markets and customers.” The standout favourite crane in Bucciarelli’s fleet is the AC 220-5 Demag, due in part to its five-axle carrier and 78m long boom. These features have allowed GCSWA to utilise the crane in almost every application in the Perth metro area or in remote regional locations. Measuring in at 14.52m long and 3m wide, the crane can fit into areas where others might not. It is also equipped with the IC-1 Plus control system, which calculates the crane’s lifting capacity for every position of the boom subject to the slewing angle of the superstructure. Reliability is important for GCSWA and not just when it comes to cranes. Bucciarelli explains that when running a privately-owned business there’s not much time to switch off, so it’s important to have a trusted team. “There’s a lot of stress running a privately-owned business, so it’s good to know that whenever I’m away from the office, it remains in capable hands” he said. “Our father has been a great source of help and expertise from his three decades in the cranes industry. His strong work
ethic and dedication to customers is what inspired us to exceed and has been critical to helping us get through the challenges which the business brings.” When Nick started his own business with his brother, he was quick to become a member of the Crane Industry Council of Australia (CICA) and now sits as the Vice Chairman for the executive committee of CICA WA. “Our family has been involved with CICA since it started, and I’m happy to continue this relationship with them. We’re passionate about the cranes industry and wanted to be part of making sure it continues to support the industry our family is a part of for years to come,” Bucciarelli said. That feeling of growth is one of the best parts of the job, according to Bucciarelli. Seeing his family brand and business grow from strength to strength has been a rewarding experience for him over the years. The driving force behind going into business with his brother was to continue building while diversifying the family brand and support loyal customers in a greater capacity. “When we win a major project, we not only want to meet or customers expectations, we want to exceed them, those are the best moments,” he said. “We’re hoping to see continued growth in our business as we head into 2019 and maintain the strong family and business reputation we have.” The firm’s fleet includes an AC 220-5 Demag.
March 2019 CAL / 29
INDUSTRY NEWS / EYEBOLTS
UPDATE TO AUSTRALIAN STANDARD FOR COLLARED EYEBOLTS AND EYENUTS Eyebolts and eyenuts are used everyday in the lifting sector and changes to the Australian Standards will impact everyone. Charles Bell, Senior Lifting and Product Engineer, explains. LAST YEAR saw the release of a new Australian Standard governing the humble collared eyebolt. Australian Standards have valuable guidance for users of lifting gear and AS2317.12018 is no exception. It contains extended detail for use as well as new requirements for markings and inspection. This new Standard concerns low tensile eyebolts and eyenuts, which are called grade 4 to align with international terminology. THE OLD FAMILIAR Collared eyebolts are a simple device. They have an eye at one end which we can connect to our slings and a thread which we can connect to our payload at the other. While eyebolts themselves have changed little over the course of many years, the changes in the Standard are worth exploring. EYENUTS ARE NOW INCLUDED The new Standard now includes comprehensive treatment of both eyebolts and eyenuts. Eyebolts have an external thread and eyenuts have an internal thread. The thread is fundamental to a safe connection to the payload. These threads come in all shapes and sizes and are of course internal as well as external with the result that eyenuts are commonplace. The previous (1998) version of the Standard remained silent on the issue of eyenuts. Including them now enables the Standard to open up a more thorough conversation about the threaded connection in general. This is valuable because it is important that we get the connection right. 30 / CAL March 2019
THE SUBSTRATE It is vital that the threaded connection to the payload is safe and does not overstress the supporting material with its threaded interface. AS2317.1 calls this supporting material the substrate. Contained within the Standard are clearer rules to set out how strong the substrate material must be. A common pitfall is to fit an eyebolt to material which is simply not strong enough. One of the advantages of grade 4 (lower tensile) eyebolts is that when lifting softer materials, the grade 4 eyebolt can offer a larger thread to use with a soft payload. This is often at a lower cost than a high tensile lifting point of similar overall size. Matching the strength of an eyebolt to its substrate is vital to achieving sufficient strength and the new Standard provides guidance on a variety of common scenarios such as: use of a nut behind a plain hole, use of reinforcing washers, and use with threaded studs. Common questions such as what grade of nut or stud to use and what tolerance on hole size is required are now addressed. THE IMPORTANCE OF THE COLLAR The defining feature of a collared eyebolt is of course, the collar. A dogger might instinctively make the distinction between a lifting eyebolt and something else purely upon the presence of the collar without giving much thought to what it does. Within the new Standard the role of the collar is now emphasised. When we use any collared eyebolt (or eyenut) it is important to understand what this means and how vital the
Charles Bell.
‘collar’ of the eyebolt is. Wherever an eyebolt is loaded in line with the axis of its thread (in a straight line), the central threaded part can contribute fully towards resisting the lifting forces. Wherever an eyebolt is loaded away from this axis, then the strength is greatly reduced and the collar with the support it provides becomes vital to resisting the lifting forces. Without the support of the collar, damage in the form of a bent eyebolt is often the end result. The new Standard provides clearer diagrams and instructions for avoiding this type of damage when the eyebolt collar cannot directly contact the payload, including the use of shims and packing washers. Ensuring that the collar is fully
supported by the payload (substrate) is important for other reasons too. For example, it provides a visual indication as to whether an eyebolt is unwinding itself. The new Standard also provides guidance in order to avert such risks. These are all examples of improved use guidance within the Standard, it is not possible to describe all of them here. Readers are urged to examine the Standard for themselves or to engage in suitable training on the subject. THE DIRECTION OF LOADING One of the most important changes to the Standard however is that it has addressed the differences between load rating methodologies that exist between low and high tensile eyebolts. In general, good quality high tensile eyebolts around the world are marked with the worst case loading orientation in mind. With low tensile eyebolts however, practices vary - but the most common method is to mark the best case load rating – that is, a straight pull (axial loading). The old Australian Standard (by the way) avoided this controversy and did not specify any WLL marking. MORE TERMINOLOGY In order to address the issue, the new Standard has clarified some terminology with the following terms: Axial loading (which is a straight pull) Lateral loading (which is a type of side loading that is never allowed) Transverse loading (also called trunnion loading). For straight line axial loading, some tolerances are given (because nothing is ever perfect). For axial loading to apply, the true direction of force needs to be within 5° of perfectly axial. For transverse loading the Standard talks about the ‘plane of the eye’ and provides several diagrams to explain what this is. Whenever eyebolts are subjected to loads that line up within the ‘plane of the eye’ this is an approved direction of
While eyebolts themselves have changed little over the course of many years, the changes in the Standard are worth exploring. loading. Again, the tolerance on perfect alignment with this plane is 5°. LATERAL LOADING When eyebolts are subjected to loads that are outside of the plane of the eye, then this is called lateral loading. Lateral loading is forbidden. The new term helps to avoid confusion of course, because people would sometimes call this ‘side loading’ and then on other occasions refer to transverse loading as side loading too! Any load which is more than 5° outside of the plane of the eye is ‘lateral’. LOAD RATING MARKINGS What does this mean for marking of WLL? Well, if a load is applied axially – this is the best case loading and the WLL of the eyebolt is fully realised. For users that expect this and then refer to the load chart table for other loading directions there is no issue. For users that are used to high tensile eyebolts that are marked with their worst-case load rating this can cause confusion and problems. The new eyebolt Standard takes account of this and now specifies additional markings. This takes the form of arrows, which must be applied to indicate the transverse load rating. Fortunately for owners of existing eyebolts and eyenuts with are large or high value there will generally be some potential to retrofit markings. INSPECTION We would be remiss at this point, if we fail to mention inspection. Extra guidance on use of eyebolts is useless if we are faced with damaged equipment to start with or if there are lifting assets on the books which clients, sites, and users don’t trust. The old Standard made a distinction between eyebolts, which have a single
purpose and stay dedicated to their payload and those that are loose gear, moving from job to job. The old Standard called these multi-use eyebolts ‘service eyebolts’. If there are eyebolts in your kit box, that’s what it means. The old Standard said that you should (that’s advisory) inspect them periodically. The new Standard has gone further than this and now directs that service eyebolts shall (that’s mandatory) be examined periodically. It also applies an inspection interval table that is very much like one that appeared in the Chain Standard (AS3775.2:2014). Looking closely, what we find is that it is exactly the same. Importantly, because this sort of guidance can’t ever cover the extreme cases the table is advisory, not strictly mandatory. We all know however that in this context, advice is hard to avoid or ignore. WHERE TO FROM HERE? It is not possible to cover all of the advice and additions contained within the Standard in this article. Users of eyebolts are urged to obtain a copy and familiarise themselves with the care and use section, obey load charts and follow manufacturer’s advice. REMEMBERING THE BASICS The very basic rule of eyebolts that everyone learns is that sometimes ‘eyebolts ain’t eyebolts’. The mysterious, the home-made and the oddball are still out there. We know they don’t comply and that they can be highly dangerous, precisely because much of the guidance in AS2317.1-2018 does not apply. In these cases, there is no rule change and the only options are to replace with a compliant eyebolt (an AS2318-2018 compliant one, or possibly a high tensile one) or to use a trusted engineered solution. March 2019 CAL / 31
COMPANY PROFILE / KITO PWB
RISING TO THE LIFTING CHALLENGE KITO PWB’s broad range of chains and lifting gear is manufactured with Australian steel and every chain link is tested beyond Australian Standards. KITO PWB is a significant provider of lifting chains, associated fittings and both manual and powered hoists to the Australian lifting, construction, mining, manufacturing, materials handling, marine and aquaculture industries. KITO PWB has been manufacturing its broad range of chains for 95 years and is 100 per cent committed to remain a manufacturer of quality Australian products into the future. The company’s broad range of chains is manufactured to stringent Australian Standards in accordance with ISO 9001:2008 approved Quality Management System. Since KITO PWB first started manufacturing lifting chains, it has been using Australian made steel from the likes of BHP, Bluescope and most recently Liberty OneSteel. This Australian made steel uses Australian 32 / CAL March 2019
KITO PWB has been manufacturing its broad range of chains for 95 years and is 100 per cent committed to remain a manufacturer of quality Australian products into the future. mined and processed iron ore. According to the company, no other supplier of chains in Australia can make this claim. The vast majority of other lifting chains sold in Australia are from Europe, North America or China. By purchasing KITO PWB chain, customers are supporting Australian made products and Australian jobs and families. KITO PWB has been distributing the KITO range of manual and electric hoists throughout Australia since 1986 and the relationship has only grown stronger since KITO’s acquisition
of PWB in 2016. KITO has been a manufacturer of hoists since 1932. At KITO PWB, every single manufactured chain link that is made is proof tested. The Australian Standards for manufacturing lifting chains state that a chain must be tested by the manufacturer at twice the working load limit (WLL). KITO PWB has always tested every chain they manufacture at 2.5 times the WLL. No other chain manufacturer has a testing regime as rigorous as this. The Grade 80 Herc Alloy Lifting chain has been a market leader for
well over 50 years and the KITO PWB mining suspension, lashing and transport chains have been popular for many decades. As the only remaining chain manufacturer in Australia, the company’s 95 years of manufacturing experience ensure the products are of consistently high quality. KITO’s passion for engineering excellence sees the ISO9001:2008 and ISO14001:2004 accredited manufacturing facility in Yamanashi, Japan, produce and distribute the market leading single and dual speed 3-phase ER2 and EQ electric chain hoists and motorised beam trolleys. These hoists are suitable for a wide range of lifting applications, with capacities ranging from 250kg to 20t. The ER2 and EQ series hoists have proved very popular with the Australian market, with many thousands being
KITO PWB also has a strong relationship with Yoke, a world leader in the manufacture and supply of lifting points, hooks and chain fittings since 1985, and has been the exclusive distributor of Yoke products in Australia since 2010. sold since their introduction. KITO PWB also has a strong relationship with Yoke, a world leader in the manufacture and supply of lifting points, hooks and chain fittings since 1985, and has been the exclusive distributor of Yoke products in Australia since 2010. Yoke also manufactures under ISO9001: 2008 accreditation in its Taiwanese facility and has also been approved by shipping societies ABS and DNV. The introduction of Yoke’s Yellow Point
Series of swivel, eye, anchor, hoist and weld-on lifting points has provided a significant boost to safety and reliability in all aspects of lifting. KITO PWB’s range of lifting products is available through the company’s valued and experienced network of approved distributors. KITO PWB is also a key member of Lifting Equipment Engineers Association (LEEA) and Lifting Equipment Engineers New Zealand (LEENZ).
KITO PWB is the only remaining chain manufacturer in Australia.
March 2019 CAL / 33
SAVE THE DATE
1ST - 3RD APRI L 2020 MELBOU RN E CON VEN TI ON & EXHI BI TI ON C EN TRE
SUSTAINABILITY | AUTOMATION
I N D U ST RY 4 . 0 | E - CO M M E R C E
IN FOCUS / UAA
ENSURING THE CRANE SECTOR HAS THE RIGHT INSURANCE COVERAGE Crane operators need comprehensive insurance to protect themselves and their business, so it’s important you have the right cover.
Michael Murphy, Shawn Borger and George Grasso.
CRANES AND LIFTING MAGAZINE sat down with Underwriting Agencies of Australia’s (UAA) Chief Services Officer, George Grasso, Chief Executive Officer Michael Murphy and major client Shawn Borger from Borger Cranes to discuss the importance of implementing 36 / CAL March 2019
the right insurance policy. Shawn Borger: For Borger Cranes, the most critical issue is getting a crane back into operation after an incident. So we rapid approvals from assessors and repairers who can jump on the crane to get it straight back to work.
Time off the road is critical time, not just from a monetary perspective but also from the customers’ point of view. When the customer expects a crane we need to have one ready, so we need people who know how to get the crane fixed and back to work ASAP and that
includes our insurers. I believe other insurance companies will take an extended period to get issues approved for a repair where as the turn around from UAA has always proved to be quick and efficient. George Grasso: When an incident occurs, we receive the incident report and the claim and we are onto it straight away. We appoint our cranes experts who work with UAA and, in this instance, Borger Cranes, we examine the extent of the damage, understand what caused the incident, identify if there are any other liabilities from another third party, determine the severity of damage and determine the next steps in terms of is it a repair proposition. We try to find a way to get the crane up and running as quickly as possible and if we are looking at a total loss, settle with the client as quickly as we can. With plant and machinery, particularly cranes, every hour that machine is not working is costing money, so our ultimate goal is to get it up and running as quickly as possible. Our reputation is based on how quickly we can act and respond and help our clients. Michael Murphy: The point that Shawn is making is really valid, it is not only the reputation of UAA at stake, it’s the reputation of Borger Cranes with his clients. He’s involved with multimillion-dollar extended term contracts and he can’t let his client down and if he does the future contracts won’t come around again, that’s the key issue. Shawn: With the Sydney market as it is, we’re operating in a highly vibrant environment and there are a lot of supply and demand issues so we can’t be waiting ages for answers if there has been an incident. We have a good repairer that UAA and Borger Cranes has a good relationship with, this really makes a difference when it comes to having a crane fixed and back into the fleet. Key for me is to see any issues resolved quickly and the crane back to work ASAP. Relationships are also important and I can ring George or Michael anytime
and they can ring me to discuss different matters. The key to the success with UAA is the relationship with the various individuals including the broker. We look at all providers, whether it our insurance, finance or tyre supplier as part of our business, we want to work together and ensure that they’ve got our backs. UAA offers a policy covering an overall amount of cranes and if we add to the fleet and purchase six new cranes in a year these are added to the policy. We talk about the market to see where premiums are going and see what impact the things we have done in the business and what the market is doing with insurance. We are continually trying to improve our business, we are embracing the rapid changes that technology is bringing to the crane sector and we are continually up-skilling our employees. Obviously, we want to minimise our risks and so does our insurer as does our customer. We want to ensure a good and safe days work. George: As Borger and other crane businesses implement more and more technology, increase safety policies and enhance the safety aspect of the work place, this does this impact on premiums in a positive way. Shawn: At Borger Cranes we are certainly trying to implement the newest and latest technology in the cranes to make improvements for the driver so he is more aware of the site, or that our foreman is more aware of risk assessment and management. If you have 20-year-old technology, there are likely to be more accidents. We’re certainly keen to embrace new technology to make operations safer. Michael: The bottom line is that the implementation of new technology can impact on the premium in a positive way. The major issue, and to Shawn’s point again, if he’s reducing the amount of claims that he has through accidents, then clearly the less claims he has the better his premium is going to be. It is also a duty of care. As Shawn said earlier, anything that allows his drivers and operators to be safer is a duty of care. In my opinion Borger
Cranes is at the forefront of this in the crane industry. Shawn: We want to be for many reasons. Our business is based on family values. We employ nearly 300 people. So, if you have a family of four there are 1200 people that rely on Borger Cranes, so we want to make sure that we eliminate as much risk as we can so we have a safe and successful business for all these people. The safety side of our business is very important and technology gives us an edge over the competition. Take trailers for example. People can buy a semi trailer to carry the counter weight for $25,000. We buy top of the line product at a premium, which makes transporting counter weights easier, faster and safer. We have pinned counter weights instead of them being tied down and we have a huge variety of trailers which make our operations much more efficient. We’ve bought something like 50 trailers from TRT, which have contributed to making our business much more efficient in terms of economics and safety, they’ve made a major contribution. It’s amazing to see the savings we can make just from a semi trailer. A person working with chains can take 30 minutes to tie the counterweight down, where as with our trailers it’s all pinned and done within five to ten minutes. You save money on wages with faster crane set up faster times and it makes you look more professional. When one crane company takes 30 minutes to set up and another can take three times longer than that, you’ve got to remember that the customer is paying for that time, it’s all down to technology. This type of thinking is now coming into our industry but we’ve been implementing it since we’ve been in business and its been a big aspect of our game. One of the most important issues is the relationship you have with a broker and that’s a big up side of working with UAA. From a day to day perspective I can talk to Andrew at the brokerage about renewals and additional cover for new cranes etc. but when it comes March 2019 CAL / 37
IN FOCUS / UAA
to major projects that we are involved in, we certainly feel comfortable with UAA. On the bigger jobs there’s less risk but the paperwork is more stringent, safety processes on the jobs is better but with so many people on these sites, the risk escalates because of the size and complexities of the job. And those clients are the likes of CPB, John Holland and Bouygues Construction, if there’s an issue big players don’t want a little insurance company with no real backing. With UAA being in Australia is a key issue for us. George: Relationships are important. For example, Shawn bought a brand new crane and picked it up at the weekend but the insurance hadn’t come through, we were able to provide cover over the weekend. Some of the technical aspects of these major projects can include some ambiguity and greyness in the appropriate covers. Shawn knows he can pick up the phone and call me directly to better understand if certain issues are covered or require additional cover. We provide support directly and through the broker as well. As a business, UAA understands mobile plant, machinery and cranes in particular. Shawn: Unfortunately, most people are sick of dealing with insurance businesses and banks. From our perspective we’ve got a really good insurance company and bank and I like dealing with both. I think you’ve always got to remember that it’s the people not just the industry. George: Michael and I talk to Shawn on the phone and we catch up at least once a year, particularly at events like the CICA conference. In doing this, we learn what’s going on in his business and in the industry at large, particularly when you talk about technology and the changes it is bringing. As an insurance company these meetings help us understand what the new risks might be, what changes we might need to make to our policy wording to suit the new needs of the industry. That relationship is really important because 38 / CAL March 2019
as the industry changes and becomes more technically aware, we need to evolve to be innovative around the insurance product that we sell as well as providing the right services around that product. We need to ensure that we have the right cover to suit the need in the industry as it continues to evolve. Shawn: CICA events are important and the businesses that turn up to the meetings and the annual conference, including UAA, show me that they actually want to learn about the industry and not just sell to it. If you don’t attend and understand what’s going on, you’re really basing opinions on hear say and statistics. If a supplier is genuinely aware of the changes that are happening in the industry and how much safer we can make it, a business like ours feels more comfortable dealing with them. Interestingly, I don’t see other insurance companies putting in the time and effort at these CICA events that’s for sure. Michael: Yes, I think an important point is that we specialise in this sector. We are not an insurance company that touches multiple products and multiple assets, our heritage is cranes and our policies have been specifically designed for machines that lift. We’re Australian, you can pick up the phone and speak to us as opposed to competitors that are limited to certain numbers regarding claims and then they hand it off to a syndicate in London. They tend not to care about relationships it’s all about the mighty dollar. Shawn: Specifically designed policies make a big difference – UAA offers a really great package. George: Our products and services aren’t just about damage to a machine, they also cover the risks associated within a crane company and can relate to machines hired on a short-term basis. It can relate to the types of goods that they are lifting and the value of those goods. For example you can be lifting a $2million MRI scanning machine which most other insurance companies wouldn’t automatically cover, where
we would. Multiple crane operations where more than one crane is lifting, we provide automatic cover because we understand the industry. We are talking about business interruption insurance. We offer lease payment protection as most crane operators will finance a very large crane, very few will pay cash. The lease payment protection is straight forward, if the crane is damaged and not working, we’ll continue to make the lease payments whilst it’s being repaired. But that’s a big deal because the lease payments might be up to $15,000 a month and for the larger cranes $30,000 to $40,000 a month. Shawn: You can imagine, if you’re a small or new business, and you have an incident and your crane is off the road for six to eight months, finding the repayments could send you broke. You can make savings whilst the crane is out of action, but if you’re not providing a service your customers won’t wait and might not be there when you’re back on the road. It doesn’t matter if you are a small or big company, having equipment out of action is a very difficult issue to manage. Michael: Crane operators like our policies because they have been specifically designed for plant and equipment, especially cranes. To have all the different covers we have mentioned, you would normally have to engage numerous different insurers. With UAA, you can get them under the one policy. The big difference is, if you had three or four different suppliers providing these covers you would have to go each with a claim, and that’s a nightmare for crane operators and owners. Shawn: That kind of ‘umbrella package’ is like us. Why do customers come to Borger Cranes? Because we offer small, medium and large cranes, a crane for every application and we have a relationship with the customer. We want the same from an insurance company, it’s about being offered the right packages and having the right relationships to go with them.
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March 2019 CAL / 39
IN FOCUS / LIEBHERR
SERVICE AND SUPPORT THE LIEBHERR WAY Aftersales support doesn’t just include service and spare parts back up. It can define the culture of the crane supplier and its commitment to supporting the customer, day and night. THE CRANE INDUSTRY is only as good as the support it receives from suppliers and manufacturers. Supplying a new crane is generally the first step in a strong alliance with the customer. Steve Hogg, National Service Manager for the Liebherr Mobile Crane Division, explains how his company approaches service and support, major inspections and the importing of used cranes. He puts particular emphasis on the importance of getting customer support right. Hogg started as the National Service Manager in the January 2015 and had been the Eastern Region Service Manager since April 2013 for the Mobile Crane Division. The Mobile Crane Division covers all cranes produced from the Liebherr-Werk Ehingen factory and includes all-terrain cranes to 1200t, rough terrain cranes to 100t, compact cranes to 50t, truck-mounted cranes to 60t, lattice boom mobile cranes to 750t, telescopic crawler cranes to 220t and lattice boom crawler cranes from 350t-3000t. “I’m responsible for the Aftersales side of our business in Australia and New Zealand which includes facilities, in Perth, Melbourne, Auckland, Sydney and Brisbane. We also operate remotely in the Pilbara, from Christchurch in NZ and out of Adelaide where we look after South Australia and the Northern Territory,” he said. “We have 28 qualified, factory-trained technicians, two factory qualified and certified welding technicians and five apprentices. We have found that our Apprenticeship program allows us to introduce young people into our business to train them the ‘factory way’ and enable them to deliver the high level of customer service, knowledge and experience that we expect of our team members. 40 / CAL March 2019
Steve Hogg, National Service Manager at Liebherr.
“Our technicians are all very portable and move around within and between the countries and areas we look after. We don’t give it a second thought when it comes to organising a technician to visit a crane, we get our guys anywhere they need to be,” he added. The service team also includes highly experienced and skilled staff working in the technical services area. Their experience with the products from Liebherr-Werk Ehingen is second to none. “Those guys are the ‘go to’ for the deeper engineering issues, common fault finding and operational issues, not only for our team but also for our customers. Along with myself, they have direct contact with the factory. This keeps the communication channels clear and swift so we can get back to our customers really quickly. Given that we are talking to Germany on the other side of the world, we can normally get an answer back to a customer within 24 hours and sometimes over night,” Hogg said. “Our field service and technical services team are focused on our ‘Customer Experience.’ This starts with the first phone from a customer. If there’s a
technical problem, we have staff with well over 20 years’ experience on the Liebherr product and a lot of factory training behind them. “If we come up against a problem we can’t fix locally, we direct communication to the factory to obtain more technical details and support. Sometimes we are faced with more difficult issues that require a specialist factory technician to fly directly out to the crane. He or she may come into Australia or New Zealand from Germany, Singapore or the Middle East; it depends where the specialist is at the time. Our factory are very supportive of our product, our customers and of the Mobile Crane Division in Australia and New Zealand, so it’s not problem to organise this level of response.” The Liebherr aftersales team understands customer support is paramount, day or night. “Every member of our team will answer their phone, at any time of the day or night and, as a business, we support that. We know the level of support our customers need and our staff know what our service strategy is,” Hogg said. “It might be late on a Sunday night
when the phone rings, but our guys will answer it and sort out the issue regardless of how long it takes. We’re flexible around work times and other issues to allow for this kind of support of our people to support our customers,” he said. “Liebherr is a company that wants to support its product and therefore our customers have unlimited access to all of our team for as much phone support as they need. There are companies that charge for phone support and don’t deliver it free, however we’re not like that, we’re a company that really supports its customers.” A large area of the Aftersales strategy is to ensure that each facility has spare parts stock and support. The company backs this up with a national and international delivery regime that allows Liebherr to get parts to its customers, whether they are in a remote area or in a main capital city. “We also service New Zealand, PNG, Fiji and some of the smaller islands around Australia, so we’ve got a great distribution network which allows us to get goods out of the factory, either in an express delivery within five to six days (if they are available at the time from Germany and everything goes to plan) or on our weekly console. We bring in two airfreight consoles in every week to Perth and Sydney. These leave the factory on Monday and Thursday nights and are delivered directly into our Perth and Sydney facilities for distribution from there,” he said. There are 11 people in the spare parts department headed up by the National Spare Parts Manager, Manson Tong. The team includes parts interpreters and warehouse staff who control the procurement and distribution networks respectively. “Our spare parts team operate an after-hours parts service for emergency breakdowns too, this is all part of the customer service we offer,” Hogg said. Liebherr also has a strong focus on training. “We have a technical trainer who delivers factory accredited training here in Australia for both our technicians and customers alike, he attends the factory
regularly to obtain accreditation to deliver the courses which are to the exact same standard as the factory,” he explained. “Our customer training is conducted in each of our locations and covers topics from service and maintenance to diagnostics, inspections, LICCON 1 and 11 the influence of wind. An annual calendar is produced and circulated to customers. “On the technical side, every year we send three-quarters of our technicians, on a rotational basis, to the factory for training which is normally a two week visit. They get practical experience with access to a variety of cranes as well as theory, so it’s not all sitting in the classroom, it’s hands on training, getting your hands dirty and engaging at a practical level.” In the third year of its apprenticeship program, each apprentice is sent to the factory for a nine week ‘Basic Engineers’ course. “We specify this timing because we find that by then an apprentice has been in the business for a couple of years, they’ve learnt the terminology, they understand the importance of customer service and the standards we expect. So in their third year, we send them to the factory where they learn a lot in a relatively short period of time. This is backed up with paperwork, documentation, a computer and hard drive full of technical know how and information. This really gives them a
licence to start learning,” Hogg said. “I always say it takes between six and eight years to get a technician to a level where they are self sufficient to fix a crane, of course there’s a lot more that goes on in the background of how and why we deliver the service that we do and prepare our guys for this.” The apprenticeship program commenced four years ago and in early January 2019 the first apprentice qualified, and now every year an apprentice will become a qualified technician. “We are now in a position to feed in new apprentices very year, we hand select them, so it takes a while to find the right people, Hogg commented. “The retention rates across our business are fantastic. More than half the work force has more than five years and a quarter have more than 10 years. That’s pretty good considering the Liebherr family only bought back the business from the local dealer at the end of 2006.” DO WE ALWAYS NEED A TECHNICIAN ON SITE? Liebherr recently released its latest remote diagnostics application with the new cranes. Where fitted, these cranes feature remote diagnosis that works off the 3G mobile phone network so wherever there is a public mobile phone connection they are able to access the crane. “The system shows a member of our Aftersales support team exactly what
Completely overhauled, repainted and leaving the yard as good as new. March 2019 CAL / 41
IN FOCUS / LIEBHERR the operator is seeing. We log into the crane and immediately see the LICCON computer system. We can see what the crane is doing, see all the parameters of the crane, how its been configured for that particular job and a range of other information,” Hogg said. “From that information we can talk to the operator and help to correct an issue or change a setting or a parameter to make it work the way that he or she would like it to work. The system can save a lot of time in terms of getting a technician to site.” The Liebherr service team is also responsible for major inspections. “Major inspections are governed by Australian standards and Australia is the only country that calls for major inspections so they are unique to us and to our customers,” he said. Initially, the company will work with the customer to understand what the cranes have been used for and how they’ve been serviced and maintained during the course of their life. “We also work with our systems which provide details of what parts have been sold for that crane, what services we’ve done, how regularly certain items have been maintained. Some of these areas are specified in the standards that we need to document and relate to in the scope of work,” Hogg said. “Once we understand some history about where the crane, we will inspect it (which may be) on a job site so it doesn’t interrupt the customer, we talk to the operator and have a look at the crane, we conduct a few tests and carry out an initial inspection to get a deeper understanding of the cranes condition,” he said. “From there we provide a quote with a scope of work that meets all of the standards and the manufacturers requirements. Most manufacturers will have some recommendations of work that needs to be done at certain times or ages on the crane and we are no different. We have a lot of internal information and guidance material provided by the factory for doing this work.” Once the quote has been provided there’s more communication with the customer, details of the quote are explained, what work is needed and why. 42 / CAL March 2019
The crane is then booked in for the major inspection at a convenient time for the customer and an independent engineer is engaged to examine the crane as the work progresses. “The engineer might visit us multiple times during the course of the work,” Hogg said. Throughout the process other third parties examine the crane, including crack testers, who conduct specific crack testing to the manufacturers recommendations. “Customers are welcome to visit our facilities, at any stage, to assess their crane,” he added. “When we get to the completion stages the crane has another full functional test, inspection and sometimes a CraneSafe as well. Generally the crane will be due for that anyway. We then produce a report including photos from the scope of work, service reports and reports from the 3rd parties that we’ve engaged and the engineers report. The engineers report is probably the most important because that document says the crane is in safe working order and has a new life up until a certain date providing its maintained to the manufacturers recommendation. “We also produce a stainless steel plate that’s fixed to the front of the crane and this confirms that we’ve conducted a major inspection, it specifies the job and serial number and when the next major inspection is due. That’s important for cranes to get on site with the unions and other controlling and safety bodies. The team has conducted major inspections in QLD, NSW and WA and is about to undertake its first one in VIC. “Recently, we had a 300t crane, the LTM1300-6 from Everwilling Cranes in for a major inspection in our Sydney facility, which went perfectly. The customer opted to have the whole crane painted so it came out of workshop and paint shop looking and performing like a new crane. We had a very happy customer and Wayne is a very happy operator, he loves that crane,” Hogg said. So what happens when a used crane is brought into the country? The rules surrounding the importing of used cranes essentially say that if the records for the crane aren’t available it needs to have a
full inspection. That full inspection, according the Australian Standards, is very similar to a major inspection. “The authorities need to know the history of the crane, that it hasn’t been over loaded, that it doesn’t have cracks through it and, obviously that the crane is safe,” Hogg said. “With the importing of our cranes we have a ‘factory backed’ system where our factory does the full inspection of all the specific main criteria and provides us with all the inspection documentation. And test reports. Because the documentation is coming from the German manufacturer it is accepted by the Australian authorities,” he said. “So when we bring a used crane in it is ready to operate apart from some local content that we might need to put on it, like larger wheels and tyres, guard widening or narrowing, the normal Australian design rules around lights, for example. “Used cranes can be operating anywhere in the world, but generally a lot will come from Europe. LiebherrWerk Ehingen has three workshops and the cranes will go into one of these. They are subjected to the inspection and testing regime signed off by the factory. So we don’t get a crane direct from a customer or from the field, it will always go through one of our factory work shops,” Hogg said. European customers are generally very different and much larger than Australian customers operating much larger fleets. “In Europe, customers will change a large portion of their fleet every three to five years. A customer may approach the factory wanting to ‘change out’ 40 cranes in a year and of these, some will go to dealers, a percentage will come to us and others will go onto the global market,” Hogg said. “We have a used crane manager in Australia and he communicates with the factory to confirm what type of cranes customers are looking for in Australia. It’s a global network that we are operating and like a lot of things, it’s born around communication and the needs we all have. At Liebherr, we live and die by the sword, our performance speaks volumes and that’s what we live and die by.”
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IN FOCUS / MAX CRANES
1200T LIEBHERR BRINGS RENEWABLES FOCUS TO THE MAX The largest telescopic crane in the southern hemisphere is being put to work in the renewable energy sector. Cranes and Lifting Magazine reports. The 100m extended main boom length is the longest in the world.
44 / CAL March 2019
MAX CRANES RECENTLY welcomed the largest telescopic crane in the southern hemisphere to its fleet. The $10m, Liebherr LTM 11200-9.1 all-terrain telescopic crane has a capacity of 1200t and will allow the Upper Spencer Gulf business to expand its capabilities in the construction and maintenance of wind farm towers across the country. It will also be used for construction and heavy lifting activities throughout every market that requires specialist heavy lifting. Managing Director and co-founder of Max Cranes Mark Kuhn says the business has been looking to secure the Liebherr all-terrain telescopic crane for a number of years. “The business spent a lot of time on the selection of the best type of crane to bring into the country that will be a problem solver to all market sectors,” Kuhn said. “The LTM 11200 has a number of benefits that will set the business apart from the rest. The crane, albeit huge, is efficient and economical in its ability to mobilise/demobilise to project sites and is very agile and flexible on site.” By any measure, the crane is impressive. Its 100m extended main boom length is the longest in the world, and then there’s the 126m luffing jib that goes with it to provide a maximum lift height of 188m and maximum reach of 136m. While the maximum capacity of 1200t is something that will never be lifted in real life, the capacity of 112t at a 100m tip height and 105t at a 30m radius (59t at 50m) give an indication of real world capabilities. The crane’s ability to mobilise
quickly and efficiently is unparalleled in comparison to other crane types of a similar size and capability. The LTM 11200-9.1 is the strongest telescopic mobile in the market and offers the longest telescopic boom. An increase of capacity is realised with the Y-telescopic boom suspension, short erection times, excellent mobility as well as comprehensive operator comfort and safety configuration are key features from Liebherr. Max Cranes has formed a heavy lift team of 18 around the Liebherr LTM 11200 and 400t and 500t all-terrain cranes. It’s made up of existing staff promoted to work with the new crane and external recruits with the requisite skills backed by an in-house technical team with CAD, engineering and drafting capabilities. The team received extensive training from Liebherr factory technicians, including Liebherr’s Sophie Albrecht, flew to Port Pirie and Port Augusta via helicopter to see that the crane had arrived safely. In late November, Max Cranes celebrated the cranes by organising the 1200T Arrival Day attended by over 400 key industry leaders, clients and dignitaries. The following day, the business invited the local community, including school children to take a close up look. Over 500 people attended the community day, and show bags filled with branded Liebherr and Max Cranes merchandise were handed to the very excited school children. Everyone was able to touch and feel the machine and get an idea of its impressive size close up, as well as get an operator view from the driver’s cab. Kuhn said work prospects looked good. “As of October 2017, there were 196 wind turbines operating in SA and if they needed a rotor (the three blades and hub) removed for maintenance the crane had to travel from interstate. Within the next 18 months SA will have 287 turbines with the construction of Lincoln Gap and Willogoleche farms in SA already underway.” The new crane is the latest achievement for the leading Upper Spencer Gulf
Over 400 people attended the arrival day.
business that has been helping workers reach the heights of our tallest regional infrastructure projects. The Federal Government supported the acquisition through its Regional Jobs and Investment Package. “There has been an upward growth curve in our workforce over the past 12–18 months as the infrastructure, power and energy, mining, oil and gas and other influencing markets have started to recover from the downturn of 2014/15,” Kuhn said. “We’re looking to further bolster our position in the Upper Spencer Gulf region with the ever-expanding renewable markets, the commitment of GFG Alliance to the Whyalla Steelworks and the expansion of surrounding mining and infrastructure projects within the region. “Max Cranes is also focused on strengthening our position within the Adelaide market, specifically looking to find solutions to clients in all market sectors.” Max Cranes employs more than 130 people across its head office at Port Augusta and additional depots at Whyalla, Port Pirie, Moomba and Adelaide. Its fleet of 38 All terrain cranes range from 15 to 1200t machines. The business also supplies scissor lifts, knuckle booms, and heavy haulage transport services.
Max cranes is currently the sole crane provider at the Port Pirie Nyrstar Lead Smelter which has recently undergone a significant platform redevelopment and recently secured a five year single source contract with oil and gas giant Santos. However, its presence on wind farms is set to grow further with South Australia’s burgeoning renewable energy sector. Currently, Max Cranes 400t and 500t are the cranes used in the maintenance of wind towers, to lift off the rotor – the three blades and hub – and allowing a changeover of gear boxes and other equipment in the turbine. The acquisition of the 1200t Liebherr will now allow for future maintenance of the heavier and higher towers we are seeing built today.
KEY FEATURES OF THE LIEBHERR LTM 11200-9.1 INCLUDES: • 110m long telescopic and 22m telescopic extension (10m + 6m + 6m) • Capacity 65t at the 100m, suspended telescopic boom • 126m luffing jib • 60.5m long fixed jib, optionally hydraulically adjustable • Active, speed depending rear axle steering, all axles steered • Economical transportation
March 2019 CAL / 45
IN FOCUS / HUMMA
WHERE TO NOW HUMMA? Cranes and Lifting Magazine gets an inside look at the Humma range of pick and carry cranes.
Humma 55 has an 80km/h road speed.
THE HUMMA RANGE has evolved from its foundation in 1996 to producing a range of models, culminating in the release of the worlds largest articulated pick and carry crane with auto levelling. Cranes and Lifting Magazine was interested in the plans for the range and how the new Humma 55t will impact on the industry. We spoke to DRA Industries founder, Peter Dalla Riva. CAL: DRA was established in 1971 and was operating in other industries when the Humma project was launched in 1996. Why was the pick and carry crane market chosen when DRA had no design background and knowledge of the market? PDR: In 1984, DRA acquired Construct Engineering, an experienced design and 46 / CAL March 2019
build business in the field of material handling. The in-house experience both at the engineering and manufacturing level was high and diversified under DRA stewardship. Construct expanded, carrying out design, build, install and commissioning projects throughout Australia and later overseas in New Zealand, Ireland, Botswana, India, Qatar and Italy. The flow of overseas projects diminished and with a skilled group of staff it was necessary to find alternative work or retrench. Rather than lose the company’s skill level, other engineering markets were investigated. Following an Australian wide survey, the pick and carry crane market was chosen, as the industry confirmed it was open to change. At the time, there was only one manufacturer, Franna in Brisbane, the
other was Linmac in Perth which had recently ceased operations. The first Humma 18 was built in 1997. CAL: Without experienced crane engineers how was the Humma specification and design established? PDR: It was a steep learning curve. During the period 1998/2000, pick and carry crane owners and others, made jokes about Construct Engineering and the Humma when early models had occasional breakdowns in the field. We saw it as being part of debugging of early designs. The design team had not designed a crane with the exception of an engineer from Linmac, but the range of design experience was considerable over a variety of industries, food processing, cereal
storage and transfer, fertiliser blending, storage and dispatch and a range of specialized items of plant. One such item of plant is the hyperbaric chamber at the Fremantle Hospital for treating burns patients. With this wide range of expertise the Construct engineers adopted a specification and design criteria not used by either Franna or Linmac and unknown by the market. Even today, Humma has difficulty in gaining acceptance with some buyers after more than twenty years of manufacture. Your question goes to the heart of design and specification when designing manufacturing plants and machines. The design criteria includes that it must be safe to operate, it must be reliable as often they run 24/7 and componentry must be quality extending the working life before major overhauls are required. The buyer will consider all of the costs to the major overhaul, purchase price, maintenance, downtime and operating costs. Humma takes all of the above into consideration and more, and after twenty years of operation there is the proof. The air suspension, minimal wear and no replacement on any Humma to date, articulation joint after fifteen years one millimetre wear and no line boring required and fabricated boom damage is rare and only when operators exceed the design safety limit. CAL You have explained how the engineering teams’ experience in other industries is adopted in the Humma design, but were there specific design and objectives? PDR. Yes, there was a range of technical criteria covering safety, reliability, low running and maintenance costs and a design capable of being used on all future model. If you look at all Humma models, from 20t through to 55t, the footprint is the same only the size changes to suit the lifting capacity. Standardisation was an integral part of the design criteria set in 1996. Also, the initial plan was to build about thirty Humma over a period of a few years, having them available for dry hire, for heavy construction and maintenance in the mining industry. There was no
plan to sell the crane’s various models as they were developed in the initial ten years as this would enable Construct to track performance and incorporate the upgrades into new models. The 1996 specification has been followed and the benefits are now well proven. Take the footprint, it has become heavier with size with no warranty issues as debugging of earlier models has increased reliability dramatically. Because of the design changes all current models 25t, 35t and 55t do not have a problem attributed to standardisation. The air suspension introduced in the design specification in 1996 was laughed at and industry operators said a crane must have a rigid leaf spring suspension because Franna and Linmac cranes used them. The opposition could not offer any technical reasons why air spring could not be used. Construct designed and tested a number of versions and, yes there were failures in the field. The development cost was high but perseverance won the day, the Humma air suspension has contributed to the quality and performance it has shown over many years. Damage to the crane when working comes down to operator misuse such as over-lifting. The major damage occurs when the crane is driven especially at high speed. The air suspension confines the road conditions to the axles as the air spring absorbs most of the vibration and does not transfer it to the crane structure, this destroys bearings, cracks welds, enlarges the articulation joint, increases cabin noise and loosens bolts and fittings. Leaf spring suspension exhibits all of the above problems and although this model of crane should not exceed 80kph, if this is exceeded the driver can lose control when vibration is high. Air spring as designed and installed in all Humma, has been tested at 105kpm on Humma 35 with the driver having full control. Modular construction was another design feature to enhance the speed of manufacture in the case of the cabin, ease of assembly, ease of replacement in the event of a turnover and by mounting on rubber supports reduces cabin noise from engine and road whilst driving. The noise level is well within the
standard at 65 to 70 decibels. The industry survey established that the market wanted a crane with fully powered booms which did not exist, larger reach, heavier lift capability, more comfortable ride, greater reliability, lower maintenance and operating costs and increased safety. It has taken time, but Construct has met all of the survey and more, worthy of mention is the automotive Cummins engine used in all three models, as is the driveline. The engine power can be electronically adjusted from 230hp to 315hp. Apart from saving in standardised parts the engine has been tested against industrial versions achieving up to 25% lower fuel consumption with lower pollution. CAL: You have covered the Construct team achievements, so before we address Humma 55 development, how do you see Humma in 2019? PDR: It has been a long, expensive road with many technical obstacles and a number of setbacks, but we now receive regular positive feedback resulting in orders for all three models. Between 1996/2000 the market was small, MAC25 had been released but the market had been starved of R&D and innovation, the AT40 was developed but not yet seen. Construct had just commenced and by 2017 had gone from Humma 18 to five models culminating with the most advanced in Humma 55. In 2018 this model completed twelve months of field trials. The Construct team and management have pursued the original specification of one footprint for all models, modular construction and improvement in each model. The industry is seeing that Humma has a high degree of safety, offers the longest reach, has the highest lift capacity, established high reliability, low wear with low maintenance, comfortable ride and very low fuel usage. All designed and manufactured in Australia using quality componentry by an Australian company about to celebrate fifty years of trading. The commitment to R&D is entrenched and yes, the initial buy price is not low, but March 2019 CAL / 47
IN FOCUS / HUMMA
all other ongoing operating costs more than offset the difference. CAL: Humma has introduced new technology to the pick and carry market, but how did Humma 55 come about? It is a big jump from 35t to 55t. PDR: The answer is we listened to the market. MAC25 was well established in the mining industry but with heavier components being installed in mining equipment, the need for heavy duty pick and carry existed in the range of 35 to 40t. Humma 35 could meet some lifts but not all. Discussing the requirement with Rio Tinto and BHP maintenance, a crane capacity of 40T appeared to be ideal. As most Hummas are in the construction and mining sectors, the Construct team prepared a specification for a Humma capable of lifting and moving a weight in the range of 50t to 60t. It also had to be suitable for driving on the road. The established and proven footprint could be used and enlarged for Humma 55, the drivetrain was well proven and in use in the 25t and 35t. However, it was evident was that lifting weights up to 55t needed a very confident and safe operator and this could be a problem. The design team developed controls that de-skills the crane operation, giving the operator maximum visual load control and crane control whilst moving the load and this led to the development of the dynamic load chart and the dynamic hydraulic suspension. The 2018 field trials confirmed these innovations greatly increased the safety of the crane. The design team had the benefit of twenty years of development using the 1996 footprint but had the challenge in establishing loadings for tyres, rims and axles. Humma 55 has an 80kp/h road speed and the combination of hydraulic and air suspension produces a safe and comfortable ride. Since its release, we have been surprised in the demand for infrastructure projects, upgrading state rail lines, road bridges and tilt panel positioning. It appears other uses will be found by the crane industry although the market is mining services and maintenance. This four million dollar R&D project 48 / CAL March 2019
Humma 55 features a dynamic load chart.
was launched not only to meet the demand of a specific market sector but to see if the pick and carry crane industry was ready to move to larger cranes. Monitoring Facebook responses and the level of enquiries, it appears it is. The design team see no technical impediment to building a 100t crane, if the demand arose. CAL: The crane industry will be looking to see Humma 55 in operation. When will the first unit be delivered and are you concentrating on mining? PDR: Humma cranes can be found on a number of sites in Australia and Papua New Guinea. The common models are the 25t and 35t with Humma 35 being the preferred model. Humma is found at ALCOA, Rio Tinto, Harmony Gold, Newcrest Gold, CPB Contractors, John Holland and many others. Humma cranes are also sold and dry hired to contractors carrying out major contracts. There were six Humma 35s on hire to CPB Gorgon Project for up to five years. The first of eight Humma 55s is scheduled for delivery early 2019 to Victoria. The DRA company is not considering large production as its success is quality, service and innovation. Existing Humma owners will have preference as they have been loyal and supportive, however we would like to see it in other markets. CAL: Having developed the flagship Humma 55 is it the end of R&D for Humma or are there other projects
scheduled. Where to now for Humma? PDR: Humma has reached the first objective to produce the safest, most reliable and efficient range of heavy lift cranes. The second objective is to reduce fabrication costs so as to ensure manufacture remains in Australia, we are now the only Australian owned crane manufacturer and our challenge is to reduce costs. This is already being addressed with the first automated welding cell scheduled for installation and operation by June this year. The majority of the welding on the crane will be done by the robot, which is capable of working 24/7 if required. It produces consistent quality welds and reduce manufacturing time. No doubt, there will be problems and it will take time to maximise efficiency, but it is a challenge we look forward to. The third objective was launched in December 2018 when Construct Engineering entered into a Distribution Agreement with Australian Crane & Machinery (ACM) to distribute and service Humma. Since the inception of Humma, Construct has sold and serviced Humma because we wanted to monitor the performance of each crane. This has proven invaluable in assisting in the debugging and upgrading of each model. ACM has sales and servicing facilities in most states and is experienced with handling other makes of cranes. Existing Humma clients can be serviced by Construct or deal with the ACM team.
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IN FOCUS / A1A SOFTWARE
UNDERSTANDING 3D LIFT PLANNING For over a decade, A1A Software has been designing software for crane and construction owners. Cranes and Lifting Magazine spoke to A1A Software LLC President Tawnia Weiss about the company’s history and plans for the Australian market. WITH SEVERAL LIFT PLANNING tools available to assist crane users create lift plans, choosing the right lift-planning product can be difficult. A1A Software LLC, Fernandina Beach, Fla., launched its first product, 3D Lift Plan, in 2008. “I’ve spent my entire career combining my understanding of equipment operations with technology implementation skills. Today, A1A Software offers other business management tools specific to the needs of crane and construction equipment owners, including telematics solutions and iCraneTrax, a fleet and personnel management software designed for the needs of equipment rental companies,” President Tawnia Weiss explained. After managing her parents’ trucking company, working in automotive service, then as a sales rep for another crane lift planning provider, Weiss saw a need for web-based applications. 3D Lift Plan was launched as an easy-to-use platform that made lift planning accessible to people who didn’t necessarily know how to use engineering-based programs like AutoCAD. “There are several lift planning tools available to assist crane users with crane configurations and creating lift plans. But the right lift planning product is more than that,” Weiss said. “It’s also a communication tool, sales tool, and risk management tool. Some lift planning provides incredible detail and accuracy but require extensive training to be able to use. 3D Lift Plan can be used by people with all levels of crane and rigging knowledge and computer/technology savviness. It can also be used as a communication 50 / CAL March 2019
Tawnia Weiss.
and sales tool for use in making bid proposals, communicating with other contractors, and presenting information in a way that non-crane users can understand,” she said. As far as iCraneTrax goes, there are many fleet management tools on the market, but iCraneTrax was designed to be robust enough to manage mixed fleets of the most complex equipment, such as cranes used in rental applications. A1A currently employ seven developers and are looking to add a few more in 2019. The developers have experience in computer science and engineering, mathematics, telematics integration, 3D graphics, and Unity – the engine that drives A1A 3D software. 3D Lift Plan is subscription based, with different levels depending on the customization required for your fleet. All crane data is from actual load charts, not sales brochures, so
With the standard platform you can create a Quick Lift Setup, display jobsite dimensions, create lift simulations, and produce detailed printouts. information is highly accurate. “Standard features include crane data from sponsored OEMs (LinkBelt, Manitowoc, and Tadano Mantis), the ability to select cranes, show the assembly area, and account for sling and rigging designs. Additional crane data can be purchased. From Altec to Zoomlion, we estimate that our library contains load charts for at least 60% of all crane brands and models ever manufactured.” Weiss said. “With the standard platform you can create a Quick Lift Setup, display jobsite dimensions, create lift simulations, and produce detailed printouts.” Advanced features include ability to share lift plans with other users, ability to select crane mats based on ground bearing pressure, plan multi-crane lifts, and access to advanced rigging. More than 30,000 users and 700 corporate customers in 191 different countries currently use 3D Lift Plan. North America is A1A Software’s biggest market, with Australia the fourth largest, and growing. Australian customers have access to 24-hour email support, the same as customers anywhere else in the world. In addition to English, 3D Lift Plan is available in seven other languages: French, German, Italian, Spanish,
3D Lift Plan was launched as an easy-to-use platform.
Portuguese, Chinese and Japanese. Data can be reported in metric or imperial, and international date, time, and number formats are available. “We are looking for a local
representative in Australia to provide sales, support and training. In addition, we are considering scheduling a threeday Boot Camp in Australia in 2019,” Weiss said.
These intensive training programs are limited in class size in order to maintain one-on-one instruction. The first day covers basic lift planning, while Day 2 and Day 3 teach advanced lift setup and advanced rigging, how to import Google Earth and CAD images, understanding ground bearing pressure and applying crane mats, and how to create video animation of a lift plan. “Anyone interested in either the support position or in attending a Boot Camp should contact me directly,” Weiss said. “In our experience, once a single user starts implementing 3D Lift Plan into their sales, documentation, and planning operations, contractors and construction owners begin demanding it from all crane providers, and wide-spread adoption happens fairly quickly,” she said, “in just over 10 years, nearly all of the North American crane companies that are on the American Cranes & Transport Top 100 list are users of 3D Lift Plan.”
Basic level users appreciate the Quick Lift Setup feature.
March 2019 CAL / 51
IN FOCUS / MANITOWOC
MANITOWOC POTAIN AND THE MANITOWOC WAY
Potain recently launched its two new models, the MCH 125 and the MCH 175.
Cranes and Lifting Magazine finds out the details of Manitowoc’s new model Potain tower cranes and just how well they’ve been embraced by the Australian sector. MANITOWOC RECENTLY LAUNCHED new model Potain tower cranes and the market has responded in a quick and positive manner. The company has also seen a major over haul in its manufacturing processes which has led to the range Potain and Grove brands designed and manufactured in accordance with ‘The Manitowoc Way’. John Stewart, VP and General Manager of the Manitowoc Australian operations, discusses with the growth of the Potain tower crane business, new models and how the ‘The Manitowoc Way’ is changing the company’s manufacturing processes. The price of land in Australia’s major capital cities has always been a driver for going high with residential construction. Just one look at the skylines of Sydney, Melbourne and Brisbane confirms that the tower block construction boom is far from over. This has seen great success for the Potain business in the small to medium crane range. “In NSW we work very closely with Active Crane Hire (ACH). ACH has 52 / CAL March 2019
approximately 160 cranes in its fleet and really dominate this space. The 10 to 20 storey residential building market has seen a high demand for the small and medium size topless Hammerhead cranes, but this has started to cool a little, mainly due to the density of construction and over flight issues where neighbours do not want cranes travelling over their airspace,” Stewart said. Potain recently launched two new models to remedy the congestion issue, the MCH 125 and the MCH 175. “The models are hydraulic topless luffing cranes which use a mobile cranelike super structure with a lattice boom so it looks like an all terrain super with a cylinder. The cylinder is luffing the jib compared to the typical rope luffer which features an ‘A’ frame geometry to lift. This new design is proving to be very successful with ACH,” he said. Currently, Active Crane Hire has 15 of the new models either working or being delivered. These will be replacing a number of their older topless cranes in
addition to growing its fleet. Stewart suggested the new models are in demand due to the density of construction sites. “In this current construction environment, we are seeing older, smaller buildings demolished and replaced by taller ones. Much of this construction is happening in residential areas where there is already considerable congestion. These luffing cranes provide a great opportunity for ACH and us, to supply a crane that provides a more efficient way of building on these congested job sites.” Last year, Active Crane Hire announced that it had welcomed Borger Cranes as a stakeholder and business partner in its tower crane rental business. According to Stewart, the partnership is a major milestone in the crane hire industry delivering significant benefits to the clients of both businesses. “Strategically, we see the tie-up between Active Crane Hire and Borger Cranes as being very positive, for both the businesses and their customers. Borger is one of
The Potain MCH 125 in action.
biggest mobile crane companies in NSW. I think the tie up will provide opportunities to move into the larger sized tower crane market as they work together on tier one jobs and infrastructure projects. “Obviously, they will be able to share customer information. ACH works with a large number of the small to mediumsized construction companies whilst Borger work with the major tier one and tier two construction firms. Together, I can see the business potentially moving towards larger cranes and the business will certainly have more leverage to use the synergies to grow,” he said. According to Stewart, the partnership provides clients with the best and most economic material handling solutions by combining mobile cranes, tower cranes and self-erecting cranes and having these solutions provided by the one source. “We’re happy and excited for both parties. ACH has plenty of tower cranes that need erecting and dismantling so it will be a very busy partnership. Look at the logistics side of the business. Borger has a fleet of trucks for the mobile crane business, which can now be utilised to move the tower cranes around the state. It’s a case of the left pocket paying the right pocket, keeping the utilisation high and minimising costs.” Stewart has been working with Manitowoc for 30 years, starting with
Grove Cranes, which Manitowoc bought in 2003. A restructure of the Manitowoc management saw the introduction of ‘The Manitowoc Way’, a philosophy to streamline processes, especially the manufacturing process. “I’ve been with the business a long time and, as you would expect, I’ve seen lots of changes. As a business, we were getting smarter and better with our manufacturing, but now our new management has taken us to another level,” he said. The management team has very strong manufacturing focus and it introduced the ‘The Manitowoc Way’, a lean manufacturing and factory flow process designed to provide greater efficiencies throughout the manufacturing process. “Our Senior Management is taking the steps required to ensure that Manitowoc is prepared for the future. They have had to make some tough decisions and with a fresh vision of the business they were able to accomplish dramatic change. Consolidating the old Manitowoc manufacturing facility into Shady Grove, Pennsylvania, is an example. When you take the emotion out of the issue, it was the right decision,” Stewart said. “The old factory grew and had facilities bolted onto it and had become more like a great ‘job shop’ versus a manufacturing assembly line. The new factory is purpose
built and we’re seeing huge benefits from the increased efficiencies of a production line.” Stewart said the changes are not always easy to accept, but once the improvements are seen, even the longest serving employees understand that change is necessary. “All the factories are enjoying the ‘The Manitowoc Way’ and the efficiencies we are seeing are pretty spectacular. Long terms employees have been impressed by the improvements and management is saying ‘we’re just getting started. Change can be painful, it’s the bitter pill to swallow initially, but when you take a step back and see the results, it’s a pill that makes you feel much better afterwards.” Manitowoc has a regional structure for the product lines, mobile/crawler crane and tower cranes. Each feature dedicated factory professionals working on improving efficiencies. There has been significant investment in the business with new factories built, consolidation of old factories and new systems introduced that add value and increase quality. “We place a very strong focus on design and we like to think we take the lead with innovative technology. You can see it in the design in the design of the new generation All Terrains where we are bending frame versus welding frame. It is much more efficient and more cost effective,” Stewart said. The Megatrak suspension system is another good example of Manitowoc’s commitment to design. It’s an independent suspension without a solid axle underneath. “Independent suspension is a much better system, it’s lighter and provides more flexibility to our designs. We can add more weight where it is needed versus having the axle dead weight which allows for our frames to be deeper as we don’t have the differential moving up and down underneath the crane,” he said. “With lighter and deeper frames it means you have a stronger crane with less material. We keep enhancing the Megatrak system by moving to ‘top steering’ and making weight saving measures so the cranes are getting more compact and lighter still, but also stronger.” March 2019 CAL / 53
IN FOCUS / TADANO
The ATF60G-3 is the new Tadano champion in the 60t class.
TADANO BRINGS NEW MODELS TO THE MARKET Tadano has recently added new models to its telescopic crawler and 3 axle all terrain ranges. The telescopic crawler includes track position technology, providing optimum lift performance and a boom with the largest radius in its class. EARLIER THIS YEAR, Tadano Oceania utilised its Brisbane facility to launch two new cranes, the GTC-350, the latest compact telescopic crawler and the ATF 60G-3 the newest three axle All Terrain crane. The event was hosted by Tadano Oceania Director Anthony Grosser, who welcomed customers, factory representatives and Tadano staff. The GTC-350 is Tadano’s newest compact and reliable telescopic crawler and brings the features and benefits of the GTC-Series to the smaller size class of Tele-Boom crawler cranes. This is a no-fuss machine that boasts a strong, full power two stage boom, designed for ease of transport and quick set-up without compromising stability 54 / CAL March 2019
or lifting capacity. Even with it’s compact build, the GTC-350’s ability to reach it’s full usable capacity is unparalleled and with level ground load charts up to 4 degree, a purpose built boom, self rigging systems, updated technologies and operator comfort, these cranes are in their element operating on confined job sites, piling applications and pick and carry work. The GTC-350 also features the new OPTI-WIDTH track positioning system. This allows both symmetrical and asymmetrical track positions during reduced track width operation, providing optimum lifting performance at any track width. Track width is continuously monitored by the machine and the data
is provided to the AML-C. The optimal track width operating load chart is chosen by the AML-C based on each side track position. OPTI-WIDTH asymmetric track position setups can improve lifting capacities by as much as 50% over symmetrical. The system is the ideal solution for cranes working in congested job sites at less than full track width. The crane has sufficient hydraulic power to extend and retract the track frames on demand, and the track frames do not require pinning in position once set to the operating width. The ATF60G-3 is the newest addition to Tadano’s 3 axle all terrain range. With it’s compact build, all wheel steering and long boom, the ATF60G-3 is an all purpose crane designed to manage
The new model offers optimum operation under restrictive conditions.
a range of applications in tight spaces and industrial worksites. The new drive concept, superstructure mounted rear engine and 2 axles at the front machine, creates a balanced crane whilst minimising cab noise and emissions, providing a safer workspace and increasing overall operator comfort. The ATF60G-3’s 48m long main boom paired with 4 sheaves, a short, strong base boom of 9.5m and featuring the largest radius in its class, this model provides the customer with plenty of versatility. The crane also includes a single engine, great highway speed and asymmetric outriggers. Tadano technologies such as Hello-Net and the AML-F provide the opportunity to save costs on servicing, transport and job planning preparation. The ATF 60G-3 lifts more than any other crane in its class. Tadano engineers have developed a light but strong crane with this model which is evident in its lifting capacities. The new model is up to 46% stronger at the main boom than other 60t cranes and up to 62% stronger at the jib. These capacities are achieved by combining all lifting assembly groups, from the boom, the upper and lower structure frames up to the outriggers, which transfer the resulting loads into the ground. Higher lifting capacities are also a result of the asymmetrical outrigger base, which
is a new feature of the crane. Previously, the AML crane control calculated and approved lifting capacities per crane side, where the respectively shorter outrigger determined lifting capacity for safety reasons. It now does this separately, for each individual outrigger quadrant meaning the user avoids unnecessary lifting capacity losses and increases lifting capacity significantly. The new model also features a larger operating radius and extended operating heights. The ATF60G-3 has a main boom The GTC-350 features the new OPTI-WIDTH system.
height of 48m, which allows a sheave height of up to 51m and radius of up to 44m. This provides up to 5.5 m more sheave height with the main boom than any other 60t crane and up to 6.0m more radius. It is also the most compact main boom in its class. Constructed from 7 telescopic sections as opposed to six, the 9.5m base boom enables work in low ceilinged applications for example. The Tadano operating concept offers the crane driver a wide range of individual settings. The operator can interact with the main display via touchscreen, buttons or a jog dial button according to their requirements, while all operating functions are fully adjustable allowing the operator to set the crane up to his own preference. The additional safety display also features a further camera view of the crane deck, as well as being used to safely complete works in case of a failure with the main screen.
GTC-350 KEY SPECIFICATIONS INCLUDE: • Maximum lifting capacity: 35t • Boom length: 10.9 – 27.2m • Max lifting height (boom only) 26.4m • Max lifting height (boom plus fly jib) 38.9m • Maximum load radius (boom only) 24m • Maximum load radius (boon plus fly jib) 38m • Engine: Cummins QSB 4.5 Key Features • 35t pick and carry capacity through 360 degrees • 7.2m – 12.8m extendable jib that offsets at 5, 25 and 45 degrees • Tadano AML-C LMI system • OPTI-WIDTH – Optimal lifting performance at any track width • Work area limitations with soft stop • Winches with groove drums cable followers and 3rd wrap shutdown • Unladen ground bearing pressure of 0.53 kg/m2 • Hydraulic on-the-fly track frame retraction and extension • Hello-Net Telematics • 3 remote control work lights • 3 video cameras for winch view, rear view and right side view
March 2019 CAL / 55
IN FOCUS / PACE CRANES
KEEPING PACE WITH MAINTENANCE AND SUPPORT With the opening of a new facility in Sydney, Pace Cranes is building on its success as a crane distributor and servicing and repairs specialist for over 30 years. PACE CRANES IS WELL RECOGNISED as the national distributor for MAEDA Mini Crawler Cranes and SENNEBOGEN Crawler Cranes but the company has roots deeply entrenched in crane servicing and repairs. For over 30 years, Pace Cranes has been inspecting refurbishing and repairing all brands of cranes. When the business first started it was the service agent for various brands. These included P&H Cranes, Austin Western, Grove Manlift and National Crane and managed the repair contracts for organisations like Transfield, Eglo Engineering, F&S Cranes, the Department of Defence whilst conducting service related projects for the Sydney oil refineries for Caltex and Shell refineries and also the ICI operation. Pace Cranes offer maintenance packages with every machine. This includes preventive maintenance programs where the customer is advised when the crane is due for its annual inspection. Pace also arrange for the 3rd party assessor to come to our yards for the inspection once the crane has been, serviced and any required repairs completed. The crane is then handed back 3rd party certified with the green sticker that confirming the crane is good to go. According to Pace Cranes Managing Director Anthony Heeks, support for the customer is a key issue. “We acknowledge that to sell cranes you need a high level of back up and support. You also need to have the right level of spare parts to back up your machines. We’ve been representing MAEDA for 27 years and, with that 56 / CAL March 2019
Pace Cranes Managing Director Anthony Heeks.
“We’ve been representing MAEDA for 27 years and, with that history, we know the machines and what parts to stock.”
history, we know the machines and what parts to stock.” All Pace Crane staff is factory trained by MAEDA and SENNEBOGEN factory engineers in Australia and, in addition, staff are sent to the factory. Training also includes the Pace Cranes service agent network, a network of independent companies that operate right around Australia and New Zealand, including the north and south islands. According to Heeks, throughout the three decades the company has been focused on bringing youth through the business.
“We will have put 21 apprentices through the company over the past 30 years, we’ve always been big on getting young guys into the business and teaching them. They’ve completed four year apprenticeships as a plant mechanic, including a three year TAFE course, and on completion they’ve received a Certificate 3 in Automotive Mechanical Technology,” he said. Pace Cranes was the first company to obtain CraneSafe accreditation outside of Victoria. CraneSafe was first implemented in Victoria with CICA based there. It was trialled for a year or so and then
implemented on a national basis. “We were the first company to gain CraneSafe accreditation in NSW and had two assessors qualified, myself and Patrick Mardaymootoo, our Service Manager at the time. Patrick is still involved with CraneSafe now,” Heeks said. “Patrick was our service manager for 25 years and prior to that Jim Ironside worked with us – these are all names that will be well recognised in the crane industry. That knowledge has been passed down so we have plenty of engineering experience and we know cranes.” According to Heeks, the business is focused on what it does best. “We’ve also got a wealth of experience in
“We were the first company to gain CraneSafe accreditation in NSW and had two assessors qualified, myself and Patrick Mardaymootoo, our Service Manager at the time.” the workshop team, including our workshop service manager Greg Muller been in the industry for 20 years and in his current role for five years and with the business over ten,” he said. At the end of last year, Pace Cranes opened a brand new, purpose built facility in Peakhurst, in Sydney. It’s ideally placed, close to the city but with access to the major infrastructure and motorway systems.
The new facility boasts 2800 square meters and features a 10t over head crane, 6 bays with an EPA approved cleaning facilities. In addition to mobile cranes the team carries out maintenance, repairs and inspections to Tele handlers, elevated work platforms, drilling rigs and other items of plant. The distribution of spare parts is also managed by the new Sydney facility, with parts delivered over night.
Pace Cranes’ purpose-built facility is located in Peakhurst in Sydney. March 2019 CAL / 57
IN FOCUS / ROBWAY
BIG DATA BOOSTS CRANE SAFETY Robway Safety is using data collection technology to improve operator behaviour and awareness. WORKSITES CAN OFTEN be full of hidden hazards that can go undetected when operating a pick and carry crane. If the ground slope or the crane’s attitude changes unexpectedly, the weight than can be safely lifted can change suddenly, potentially leading to disaster.
In an effort to reduce these risks, crane safety company Robway Safety developed its Dynamic Load Moment Indicator (LMI) system, which monitors the attitude of the crane and adjusts the capacity it can safely carry in real time. Jon Koval, Robway Safety General Manager, said before this type of
The LMI monitors the attitude of the crane.
With the LMI, the operator is able to actively monitor the load while it is in transport. 58 / CAL March 2019
technology was introduced, operators were required to use paper charts and load duration tables when operating a pick and carry crane. “These weren’t just unproductive, they also took the operator’s mind of the task at hand when they need it the most,” he said. “With the LMI system, an operator is now able to actively monitor the load while it is in transport, while the system recalculates the maximum capacity, lifting parameters and angle and length of the boom. “It allows the operator to see what percentage of their safe lifting capacity is at any given instant, similar to how a speed alert works within a car,” Koval said. The system was designed through a joint development between Terex and TRT. Robway developed the mathematical models for calculating the loads and boom length, while the other companies assisted in developing the algorithm to calculate the rated capacities based on the slope, boom angles and length. This was then placed into the control system to monitor the load and provide warnings through the dashboard of the crane. If a crane reaches its maximum operating capacity, it will be unable to enter any unsafe configurations but still able to retreat back to a safer position. In addition to this system, Robway has also developed a datalogging system that works similar to a plane’s black box. Originally based on European standards, the technology records every action taken within the crane to monitor operator behaviour and assist investigations. Koval said the system had immediate results when installed on one of their client’s machines.
With the LMI system, an operator is now able to actively monitor the load while it is in transport, while the system recalculates the maximum capacity, lifting parameters and angle and length of the boom. “The data can be used to figure out the cause of any faults in an investigation, creating a level of accountability for the operator. However, it can also show if an incident occurs that wasn’t their fault. It does this by recording the movements of the crane in real time, so that any time a safety feature is overridden, or the crane is brought outside its safe working envelope, an alert can be sent out,” he said. “We found that operator behaviours changed rapidly once it was possible to record what was being done with the crane.” Robway’s next key focus is data analysis, as the system can record millions of individual numbers that need to be properly interpreted in order to provide meaningful insight. This data can be used for more than just safety. Robway has been able to combine it with internet reporting to assess value of cranes, helping companies decide when to sell the crane. “We found our customers were able to use the data to find out how to get the most value from their assets. They were able to evaluate when the crane had reached the halfway point in its lifespan and could make informed sales decisions,” Koval says. Remote system accessibility is also an area of development that Robway is researching, particularly with advances in cellular network technology. The company aims to provide a system which will allow live video feed
The data from the systems can be used to help figure out the cause of any faults in an investigation.
The system records the movements of the crane in real time.
“We found our customers were able to use the data to find out how to get the most value from their assets. They were able to evaluate when the crane had reached the halfway point in its lifespan and could make informed sales decisions.” of a lift, which it believes will improve operator behaviour and collaboration, as offsite assistance can help provide assistance for particularly difficult lifts. Koval said enhanced accessibility is key for the future of the company’s offering, especially as the consumer market drives expectations within the cranes industry. “Smartphone technology has made
accessing data and information even more readily available than ever before. Users are able to pick up their phone and get what they want in seconds,” he explained. “We’re also looking to build off the multi-billion-dollar research and development happening for consumers and adapt it for the future of crane safety.” March 2019 CAL / 59
IN FOCUS / KATO CITY CRANES
One of the new KATO CR200Rf models.
NEW KATO CITIES TO BORGER CRANES Sydney crane hire business Borger Cranes recently took delivery of a new 20t KATO City Cranes, thanks to the reliability and performance of other KATO models in the Borger fleet. FOR NEARLY 40 YEARS Borger Cranes have been providing lifting and rigging services to the greater Sydney, NSW and interstate construction sectors. With over 70 cranes and depots in Sydney and Newcastle, its fleet of crawler and all terrain mobile cranes is capable of lifts from 3t to 600t. 60 / CAL March 2019
Employing 300 staff, the company is owned and run by the Borger family, and brothers Shawn and Nathan, who pride themselves on their fleet of cranes which features the newest models of most of the major brands on the market. “We work hard to provide the customer with the right lift with the
right crane,” Nathan Borger said. “And, we have a wide range of cranes to be able to provide this service. “We are also very safety focused and offer additional OH&S/EHS to our clients. We also have four full-time draftsmen/engineers managing our AutoCAD design specialist solutions
Nathan Borger, Director, Borger Cranes.
“We’ve found the KATO to be a really reliable crane. We haven’t had any technical issues and we like the Japanese approach to engineering and manufacture of the crane, it’s full of traditional Japanese values.”
in-house, and out clients benefit from these as well,” he said. Borger cranes are operating somewhere in NSW every day in sectors including infrastructure, renewable energy, mining and general construction. The fleet is continually being added to meet specific customer requirements and two recent additions were KATO 20t City Cranes. “Close to 20 years ago we had two 22t KATOs in the fleet and they performed well. Then a couple of years ago we added two new KATO CR200Rfs and, more recently, another two, so we’re now operating four KATO
City Cranes. We use these for the smaller end of the infrastructure work we have, but we mainly focus them on the construction business,” he said. “We’ve found the KATO to be a really reliable crane. We haven’t had any technical issues and we like the Japanese approach to engineering and manufacture of the crane, it’s full of traditional Japanese values.” The KATO CR200Rf 20t city crane features a number of new technologies designed to make the crane more operable in city type applications. The newly developed jib system makes for an easy and efficient jib operation and the latest Automatic Crane System (ACS) and various monitor cameras (as optional extra equipment) are available to provide safer crane operations. The KATO CR220Rf boom features six sections and is hydraulically telescopic, with a length of 6.5m to 28m and a maximum lifting height of 29.1m. It also has a fly and needle with a maximum lift height of 34.8m. “It’s also a very handy crane for the
Sydney market where we find many of the jobs have challenges like tight and compact spaces to operate in. The KATO has a tight tail swing and is a very compact crane. The operators like them and they are nice and easy to operate on site,” Borger said. The cab is designed with the operator in mind with a roomy wide cab, comfortable reclining seat and wide foot space. The slanted boom provides a wider view of the work site. Various safety monitor cameras assist with safer operations and driving. Features also include ACS with a touch panel, colour information display, which the operator can use to save on fuel consumption by checking the working time on the display. The ECO switch controls the engine speed during operation as well during driving. Up to 10% energy savings can be made compared with regular driving on flat roads. “The KATOs are out there all day everyday doing their job, doing what we bought them for and doing it well,” Borger said. March 2019 CAL / 61
IN FOCUS / EDWARDS HEAVY LIFT
ENSURING THE HOOK AND RIGGING INTERFACE IS CORRECT
In this article Stuart Edwards from Edwards Heavy Lift continues to look at the hook of the crane and other rigging component interfaces. THE TECHNICAL INFORMATION in this article will not be applicable to all manufacturer products and you should always check with the manufacturer and all relevant standards for your particular application. Having said that the items raised in this article might help prompt to know what questions might be worth asking and things to consider. CROWDING Two’s company and three’s a crowd as the saying goes. In the case of a crane hook it’s not the number of slings but whether everything can sit neatly in the hook. In the case of synthetic round slings the best rule to apply is bearing width and contact radius as per AS 4497. Figure 1A & B shows a case where the hook size for the synthetic round slings is probably not the best. For other rigging hardware, these components need to fit with sufficient such that they can find their own line of action and do not crush other slings (as shown in Figure 1C). An alternate arrangement connecting synthetic round slings that would otherwise be crowded is shown in Figure 1D.
1A) Avoid sling crowding. 62 / CAL March 2019
Figure 1B).
UNEVEN LOAD SHARE ON RAMSHORN HOOK Ramshorn hooks might be the original hippies; live life in harmony and balance and everything goes great. Maybe not, but you need to make sure the Ramshorn hook is not unevenly loaded. The maximum recommended uneven load share is 45% to 55%. Outside that, it’s recommended you change over to a single hook, a hook with a hole for a single shackle or another sling arrangement to bring it down to a single point. MAX SLING ANGLE A maximum sling angle from vertical in line with the hook is 45˚ for a number of manufacturers. This is quite generous and some manufacturers reduce this to 30˚. What might catch more people out is the out of plane angle. Out of plane is not the same as “out of body” but you might have that experience if you load a ramshorn hook with a funky out of plane sling angle, the maximum permitted side load of 30˚.
RAMSHORN HOOK ORIENTATION Orienteering is a sport in which runners have to find their way across rough country with the aid of a map and compass. We are not talking about that here but you might find yourself looking for directions north to the nearest airport if the orientation of the hook relative to the load is not correct. The hook is running perpendicular to direction the load is rotated. During the rotation the slings will rotate on the hook till equilibrium is achieved. In the alternative orientation one side of the hook would be loaded up at the start of the lift and depending on the hook configuration could be loading up the sheaves on the heavy side more as well as tilting the hook. This leads to a serious chance of the rope jumping the sheave and cutting the hoist rope. I hope you have found something useful in this article. In the next article we will cover, connection of hardware such as master links and shackles to the crane hook and lift points.
1C) Avoid crushing other slings.
1D) An alternative option.
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