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Precision Needed For Railroad Engines
Crane-Tec was called upon to do a project for a Railroad Engine Maintenance Facility. Our team of experts were asked to engineer, build and install a free-standing, 20-ton crane system in an existing facility. This new setup would be used to service railroad engines.
Special Considerations:
- The customer’s application required precise movement and positioning
- Adding a freestanding runway system into an older, existing building.
Solution:
Working with the customer and general contractor requirements, Crane-Tec engineers designed a freestanding, 20-ton crane system. We recommended variable speed control for the bridge, trolley and hoist. We also added a true vertical lift hoist.
[Our engineers design to your specific needs. That’s what sets us apart!]
Result:
Crane-Tec engineered, built, installed, and tested the complete 20-ton top running double girder, heavy duty, radio remote controlled crane and free standing runway system.
Below is a video with images for this recent project. Enjoy!
Integrating Safety With An Overhead Crane System
When a large aviation client asked Crane-Tec to build an overhead crane system, the safety of their employees was paramount to the design.
34 percent of injuries and many work-related deaths are the result of a fall from height.
We understood that taking a preventative stance to protecting employees from injury or death, and to remain compliant with OSHA standards, was an important element to this job, so we sought out an industry leader to help with the design.
SOLUTION
Crane-tec turned to Rigid Lifelines, a company at the forefront of fall prevention safety, to help incorporate a Rigid Track fall prevention system into the overhead crane design.
We engineered the safety equipment right into the monorail system that we designed and then built all of the structural steel and the system to support everything.
RESULT
- The installed overhead crane system consisted of a 20 metric ton crane with 15 ton monorail spurs. Fall protection rail was installed on each of the 18 monorail spurs and the bridge crane
- Each 58 foot long monorail spur had its own fall protection rail designed to support two people
- On each system there were two, self locking trolleys with retractable lanyards
The purpose of having the fall protection secured into the structural support of the crane and monorail systems is to protect the personnel when they’re working on the large engines.
Read more about workplace safety and rigid track systems.
Check back with us next month.
Next month we’ll highlight this entire project and showcase the cranes and hoists provided by our partners at EMH. Stay tuned!
Down with the OLD, Up with the NEW
The Challenge:
Remove two old 10 Ton Top running double girder cranes and replace them with two new 10 ton top running single girder cranes.
Special Considerations:
- The New single girder cranes needed to have the same amount of lift as the old double girder cranes
- New cranes could not have any painted surfaces that could chip or flake (Note: clean room environment)
- Precise hook spotting required for accurate hood positioning
Our Team Approach:
- Our team, armed with existing building dimensions, designed a stooled up single girder crane with a close headroom hoist to meet the lift requirements.
- The hook and lower block of the hoist were disassembled, sand blasted, and reassembled. The running surfaces on the bridge beam were kept bare metal.
- A four light state of the art hook positioning system was installed on the hoist to indicate the exact lifting point
Result:
The old cranes were removed and the new cranes installed with little to no interference to the customer production time.
How do you make a frog
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John Deere Dealer Crane
The Challenge:
To provide our customer, a John Deere Dealer, with an integrated crane system for a new facility in Indiana.
The project incorporated two 5-ton underhung cranes and runway systems.
Special Considerations:
The general contractor needed design loading for the building and runway system. Single girder cranes with low headroom hoists were used to minimize runway and building steel costs.
Crane-Tec engineers using the metal building drawing, designed a cost efficient and space saving runway system using the building frames to suspend the runway system. This maximized the strength of the building.
Both cranes were supplied with radio remote controls for safe and precise operation.
Results:
Crane-Tec supplied a complete engineered crane and runway system. The crane system was installed, weight tested, and turned over to the owner on time with a two year warranty.
Wooden Building – Crane Installation
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Dual 25 Ton Cranes Case Study
The Challenge
To provide a crane system to help our customer in their manufacturing of large concrete building panels.
Special Consideration
Our customer needed to move large concrete panels through their high capacity manufacturing process.
Our Team Approach
We worked closely with the customer to learn their manufacturing process, their material handling frequency and their performance expectations. This resulted in the following:
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Engineering, design, and installation of
– Crane runway beams and crane rail on their existing concrete column haunches
– Two (2) 25 ton top running double box girder cranes
– Engineered lifting beams to facilitate movement of the large precast panels
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Cranes were sized for heavy duty usage with high speed hoists, trolleys and bridges.
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Cranes were equipped with radio remote controls for safe and efficient material handling. The remotes allowed the customer to operate the cranes individually and in tandem.
Results
Crane-Tec provided our customer with a complete turnkey crane system that was customized to their manufacturing needs.
Warehouse Expansion Case Study
The Challenge:
To provide our customer, an electric motor manufacturer, with an array of lifting solutions for a large expansion of their facility.
Special Consideration
Our customer needed to be able to move large scale electric motors throughout their facility interacting with multiple workstations.
Our TEAM Approach:
We worked closely with the customer to learn their specific needs, workflow and expectations, which resulted in the following:
- Installing Two 25 Ton top running double girder cranes with a radio control system that allows the cranes to be operated in unison, or individually, with only one hand held remote.
- Installing eight 1-Ton column mounted jib cranes with electric two-speed chain hoists.
- Installing a 2-Ton floor mounted jib crane with an electric two-speed chain hoist.
Result:
We provided our customer with a state of the art lifting system solution that maximized their workflow and productivity and was installed on-time and within budget.
Vacuum Lifter Case Study
The Challenge:
To provide our customer, an industrial metal parts stamping facility, with a safer and more efficient way to load their laser cutting machine.
Special Considerations:
Our customer needed to be able to load the machine with a large piece of sheet metal quickly and safely. The machine was in a current manufacturing facility which had low ceiling clearance.
Our TEAM Approach:
Crane-Tec worked closely with the customer to learn their specific needs and expectations of the new system. With our combined efforts, many options were presented, including:
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Using the existing building trusses to support a Spanco underhung push-pull bridge, trolley and runway system
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Installing an R&M electric two speed chain hoist
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Using an Anver vacuum air lifter with built-in air compressor to lift the sheets with ease.
Result:
Crane-Tec’s highly skilled installers installed a state of the art lifting system in just under 24 hours, keeping our customer’s production staff with minimal down time. They are now able to load the machine more safely and efficiently.
Injection Molding Facility Case Study
The Challenge:
To provide
our customer, an injection molding facility, with a larger capacity crane to fit an existing runway system. The customer was upgrading their facility with larger machines and wanted to add a 7.5-ton top running crane to their existing 5-ton system.
Special Considerations:
The existing crane, being lower capacity, had a shorter stature on the runway rail. With the customer needing a specific lifting height capability, and the building having a low roof, our engineers and staff were up to the challenge.
Our TEAM Approach:
Crane-Tec worked closely with the customer to learn their specific needs and expectations of the new system. With our combined efforts, many options were presented, including:
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A double girder crane, which allows the use of smaller beams to achieve the low headroom hook height.
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Radio control operation which allows the operator to stand at a safe distance from the load and move through the factory freely.
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A goose neck connection from beam to end truck to maximize lifting height.
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Duel hoist to aid in larger lifts and rotating molds for service.
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A warning light and buzzer to alert others in the building the crane is in motion.
Result:
Crane-Tec delivered a custom built, state of the art crane. Following up with our customer, our staff was told with this new system, mold change down time has been cut by 2/3.
Case Study: Unique Free-Standing Crane System
Overhead crane system and workstation crane designed to spec for leading fabrication and engineering firm
Introduction
Throughout its 35-plus years in business, Crane-Tec has been equipping a wide range of industries with a wide variety of overhead crane systems, including runway systems, monorail hoists, and jib cranes. Crane-Tec has been a leader in furnishing, installing and servicing such systems. Its diverse customer base includes general industry, power plants, the aviation industry, concrete products manufacturers, the automotive industry, machine shops, place injection mold facilities, metal service centers, tool and die facilities, general fabrication facilities and waste water treatment facilities. In addition to designing overhead crane systems, Crane-Tec also does the fabrication and installation.
Often times, Crane-Tec is presented the opportunity to design a freestanding overhead crane system. Although overhead cranes are custom designed to an extent (since the span and capacity are determined by the customer’s needs), a freestanding runway system is completely custom-designed. These customizations are sometimes the result of a building not designed for overhead cranes, which was the situation Crane-Tec faced when a leading fabrication and engineering firm in Indiana needed multiple overhead cranes and runway systems in a building that was designed for a different use.
Challenges
Custom design of an overhead crane system for this customer presented some unique challenges for Crane-Tec and its engineers. When Crane-Tec surveyed the building purchased by the end user, it was confirmed that the building was not designed with overhead cranes in mind. In this situation, Crane-Tec needed to design free-standing runway systems that were completely independent from the building structure.
Another challenge was meeting the scope of work performed by the end user. As an integral part of the fabrication process, the user needed cranes to move components throughout fabrication, assembly, and loading the finished machines onto trucks. The cranes also needed to move machines in various stages of assembly from workstation to workstation within the building. In addition, the customer needed a crane system that would allow constant reconfiguration of work areas depending on what was being fabricated.
These requirements led to a unique and complex runway system that featured:
- A very large span for the cranes to keep the building’s floor clear of columns that would interfere with workflow.
- Jib cranes supported from the runway columns, which differs from typical jib crane installations where the jibs are usually hung from the building or stand independently.
- A multiple crane system to accommodate a workflow where heavy components are constantly moving.
After multiple site visits, Crane-Tec determined that a 20-ton freestanding runway system was needed, which presented its own unique challenges. First, 20 tons is a rather high capacity for a freestanding runway system being designed to fit inside an existing building. Secondly, adding jib cranes to runway columns requires special columns and footers specially engineered for this project.
The Solution
After addressing the needs and challenges of the steel fabrication and engineering company, Crane-Tec arrived at the solution of a 20-ton freestanding runway system; two 10 ton, 70-plus foot span single box girder cranes; multiple 2 ton jib cranes; and a 2 ton freestanding workstation crane. The solution was a result of Crane-Tec working with the customer to assess their needs, price out multiple options and determine the most cost-effective avenue for the customer.
It’s common for customers to compare the cost of a number of different configurations since crane availability and the location of the runway columns will impact workflow. Many other factors come into play when deciding on the best overhead crane system for the application. In this case, however, functionality, workflow and cost were the three main driving factors.
The Design Process
Once a solution was identified, Crane-Tec worked with the customer and the general contractor to design the customized overhead crane system. Since the freestanding runway system was being installed in an existing building, a site visit was needed to take accurate measurements and assess the structure’s layout.
Runway layout is the most important aspect of an overhead crane system. Generally, the customer knows the required capacity of the crane. Crane-Tec then discusses with the customer how frequently the crane will be used and the size of the loads it will be picking up to determine the classification of the crane. With this detailed information, Crane-Tec engineers design, fabricate, and install the crane system.
Installation
Installing such a complex freestanding crane system is no easy task, which is where Crane-Tec’s 35+ years of experience pays off. For the 20-ton freestanding runway system, the general contractor modifying the building had to install concrete footings. The Crane-Tec installation crew was also on site with the necessary installation equipment, including man lifts and a carrydeck crane. The Crane-Tec crew installed anchor bolts for the columns in the footing and then the columns were installed and shimmed to level. Next, the runway beams and crane rail are bolted to the columns and adjusted to meet exacting tolerances. The entire installation process took about 2-1/2 days.
The 2-ton freestanding workstation crane was installed in the same manner as the freestanding runway system. The installation time was about two days.
For the two, 10-ton, 70-plus foot span single box girder overhead cranes, the Crane-Tec crew installed the hoist and festooning on the crane girder, which is the main horizontal beam of the crane bridge that supports the trolley and is itself supported by endtrucks. Once in place, the crane girder, including endtrucks (or the wheels that support the bridge girder), was set on the runway. Assembling and setting the 10-ton cranes took about one day.
The multiple 2-ton jib cranes were cantilever style, consisting of a steel beam with a hinge on one end. The hinge was bolted to the runway column. Then a hoist was installed on the jib crane beam. Each jib took one to two hours to install.
Once all the cranes and supporting equipment were installed, the Crane-Tec crew spent a day starting up and testing all the cranes. Crane-Tec provides an overview on how to operate the equipment and safe operating procedures upon request. This is in addition to an operational and maintenance manual provided with each crane.
Results
The Crane-Tec freestanding crane system is already making a big difference in workflow and production levels for the steel fabrication and engineering firm. The two overhead cranes allow the company to move and position materials before and during fabrication, thus improving time efficiency. The overhead cranes are also utilized for unloading raw materials from trucks, loading fabricated goods on trucks, and moving steel/machines during fabrication from one work area to another.
Without the freestanding crane system, none of this production work could have been performed in the building. The only other option was for the steel fabricator and engineering firm to free up considerable space in the building so materials could be moved by mobile cranes and large fork trucks, a consideration that was not feasible from a cost or work efficiency standpoint.
The Crane-Tec crane system is providing time-saving processes and an easier workflow. The company has already justified the expense of installing the freestanding runway system, single box girder overhead cranes, jib cranes, and freestanding workstation cranes, and is well on its way to realizing its return on investment.
Plastic Parts Overhead Crane
The Challenge:
To provide our customer a plastics part manufacturer with a freestanding 10 ton crane system over existing plastic injection molding machines.
Special Consideration:
1) Limited clear height in building.
2) Spacing of machine limits location of freestanding runway columns.
3) Delicate handling of dies.
Our Team Approach:
Our project manager precisely measured the building and location of plastic injection molding machine. We located the runway column between the existing machine; this required different lengths of runway beams. The 10 ton single girder crane was supplied with a low head room hoist to overcome the low building height. We recommended a two-step variable speed radio controlled crane for precise handling.
Results:
The customer located a new machine in a different location. During the installation, Crane-Tec relocated two columns at no addition cost to the customer.
The customer is able to change large dies in the machine safely and quickly.
Steel Warehouse Cranes
Steel Warehouse Facility 10 ton cranes with dual 5 ton hoists.
Crane-Tec supplied (2) 10 ton dual hoists cranes to a steel warehouse facility in South Dakota. Considering the customers business and expertise the customer supplied steel for the project and saved thousands.
Crane-Tec crews installed the crane, crane rail and electrification successfully without a hitch.
The cranes were equipped with hoist summation overload limit devices, bridge travel limit switched and radio remotes with hoist A – hoist B selector switches for simultaneous and independent control. This is the second set of cranes the customer has purchased from Crane-Tec and we look forward to continuing to work with them as they grow.
Midwest Mine Maintenance Facility 25 Ton Crane
25 ton Top Running Double Girder Crane for Mine Maintenance Facility
Crane-Tec just completed the turn-key Design, Fabrication and Installation of a 25 ton long span crane for a mine maintenance facility in the Midwest. Crane-Tec was contacted by the General Contractor to supply drawing and assist I in the design phase.
Crane-Tec supplied and installed the overhead crane, crane rail and electrification on-time and to a satisfied customer.
15 Ton Double Girder Cranes Ship to Nebraska
(2) 15 ton Top Running Double Girder Class D cranes shipped to Nebraska
Crane-Tec was recently contact by a steel fabricator in the Midwest to supply (2) 15 ton overhead crane in a new addition that was nearing completion. The customer wanted the crane shipped in 6 weeks from contacting Crane-Tec.
We turned around pricing that day and were soon under contract to supply the cranes. Crane-Tec was fortunate enough to have that chance to work with a local overhead crane service company to install, start-up and test the cranes.
The overhead cranes were equipped with hoist overload switches, bridge travel limit switched and remote operation. The cranes were fabricated and shipped on-time to the customer ready to take off the truck set on the rails in his new addition.
12 Ton Single Girder Overhead Crane
12 ton Single Girder Overhead Crane
Crane-Tec was recently contacted to supply a 12 ton single girder crane and 300 feet of crane rail and crane electric for a Metal Wall Panel manufacturer in the Midwest. The project consisted on (1) 12 ton top running single girder overhead crane and 300 feet of 40# crane rail and 4 bar electrification.
Crane-Tec worked with the General Contractor and Pre Engineered Metal Building supplier to determine the most practical and cost efficient design. Crane-Tec crews installed the overhead crane, crane rail and 4 bar electrification in less than 3 days. Crane-Tec technicians then arrived on-site to inspect the crane and install radio remote controls.
Crane-Tec utilized a low headroom design Shaw-Box World series 15 ton monorail hoist and had the hoist de-rated to a 12 ton capacity. All controls are housed in a NEMA 4/12 enclosure and all wiring is plug-in. The hoist incorporates triple reduction, helical, oil bath lubricated gearing in a cast aluminum gear case. We had heard good things about the Shaw-Box hoist and after putting our hand on one and building a crane incorporating the hoist we know what we heard was true. This is a well made piece of equipment utilizing the best components and engineering advances.
Another project and Overhead Crane that Crane-Tec can be proud of and stand behind.
20 ton Freestanding Overhead Crane System
20 ton Freestanding Overhead Crane System & 2 ton Freestanding Overhead Crane System
Crane-Tec was recently contracted to supply multiple overhead cranes and runway systems to a leading fabrication and engineering firm in Indiana. The customer had purchased a spec building that wasn’t designed for overhead cranes and came to Crane-Tec for their overhead crane solution. Crane-Tec worked with the customer and the General Contractor to designed a 20 ton free-standing runway system to accommodate (2) 10 ton 70+ foot span single box girder overhead cranes and multiple 2 ton jib cranes.
Crane-Tec worked closely with the customers General Contractor and assisted in the design of the necessary crane footers. Crane-Tec engineers design and completely independent freestanding 20 ton overhead crane system that is capable of supporting 2 ton jib cranes. Crane-Tec also designed and installed a 2 ton freestanding workstation crane that utilized 4 ton center bay columns so the owner can easily add a 2nd 2 ton system in the future.
All the crane and structural steel were installed successfully and on-time. Electronic eyes were installed on the 10 ton cranes to keep them from touching and bridge travel limit switched were instated on the runway to reduce impact of cranes into the end-stops.
The customer’s facility is now up and running and the cranes have become an iatrical part of their fabrication process.
Safety instructions part 4
Safety Instructions for Finishing Work with the Hoist
- Raise the empty hook or loading device high enough to avoid it causing a hazard to traffic, but not to the top safety limit.
- Leave all the controls in the O- position
- Press the emergency stop button to open the main contractor.
- Turn off the safety switches for control current and main current.
- Close any mechanical brakes such as rail clamps, etc.
- Inform your foreman of any defects you have noticed.
- Inform the next operator of all abnormalities in equipment operation you have noticed.
Safety Instructions for Servicing the Hoist
- Carry out regular inspections and preventative maintenance in compliance with the instructions. Keep a record of inspections and servicing. Regular servicing and inspection procedures are necessary for the safe and efficient operation of the hoist. In uncertain or unusual cases, contact the supplier of the hoist.
- Pay special attention to the operation of the brake and limit switches, and to the condition of the hook, rope and pushbutton controller. It is essential that safety devices (overload protectors, limit switches, etc.) work correctly and are in full operating order because they safeguard against human error.
- Use trained servicing personnel authorized by the manufacturer of the hoist for servicing the hoist. The person servicing the hoist must be competent for the task and must be familiar with the servicing and inspection instructions.
- Use only genuine spare parts approved by the manufacturer of the hoist.
- Any modifications or additions made to the hoist’s structures or performance values must first be discussed with the supplier of the hoist.
- Any inspections and repair operations carried out on the hoist after an overload or collision must be discussed with the supplier of the hoist.
Part 3. Lifting the Load- Things that you do not want to do
- Do not lift people on the hook or load. Lifting people with a hoist is prohibited unless the hoist is designed and manufactured for that purpose(this must always be agreed with the supplier of the hoist). Do not go under the hook or a load. Do not move the hook or load over a person. A load must never be lifted in a way that can injure a person if the load drops.Do not operate the hoist if you know that medication, an illness, or other such handicap impairs your alertness or working ability.
- Do not lift a load that is fastened to its base or that is heavier than the maximum permissible load for the hoist or lifting accessories. A jerking or static load can cause an overload. A hoist may only be used for those loads and load combinations, and at those speeds, for which the hoist has been designed and manufactured. Raise the load high enough to prevent it from hitting objects during travel. However, do not raise it higher than is necessary for the situation. Do not raise the hook to the top safety limit.
- During hoisting and travel motion, ensure that the hook, the load, and the crane and its moving parts do not collide with objects or people. If the hoist is provided with a horn, sound the horn when you move the load in the vicinity of people who are not paying attention to the moving load. Do not move the load until you have received a signal from the person attaching the load to the hook or lifting appliance. Do not use the overload protection for weighing the load.
- Stop all hoisting and travel motions before the safety limit switches. Do not adjust or bypass the limit switches or warning devices in order to go past motion limits. Do not use the hoist if the limit switches are inoperative. If the manually-adjusted backup limit switch in the hoist has triggered, call a serviceman to the hoist and ask him to determine why the normal safety limit switch did not function. Do not use the hoisting rope as a lifting lug.
- Do not use the hoist if there are visible defects in; or damage to, the hoist, the hoisting rope, or any other hoist structure or hoist function. Stop operating the hoist if it operates abnormally (for example, a high noise level, uneven starting, or malfunctions).Using faulty equipment is strictly prohibited. If defects have been noticed in the hoist, carry out the necessary inspections and servicing. Ensure that the hoist operates properly before you start to use it again. Do not use the limit switches to stop the motions of the hoist. Hoist motions must be stopped with the pushbutton controller or other control device intended for the purpose.
- Use the proper pushbuttons intended for controlling the hoist. If you feel you are losing control of the hoist motions, press the emergency stop button. In a potentially dangerous situation all hoist motions can be stopped by pressing the emergency stop button, but do not use the emergency stop function unnecessarily. Ensure that it is safe to re-commence working after the emergency stop button has been pressed. Avoid short, jerky motions. Unnecessary short starts can cause the hoisting motor to overheat quickly. The last controller step is for normal drive. The intermediate steps are normally used for short durations only. Do not switch the controller back and forth unnecessarily because it causes wear. Avoid violent collisions into other hoists or against the buffers.
- Do not leave a suspended load unattended.
- Do not lower the hook so far that the ropes become slack.
- Do not pull a load from the side. Lower the load with the ropes perpendicular.
- Do not use hoist motions to remove the load from the hook.
- Do not weld on a hook that is not isolated. Do not fasten a welding electrode to the hoisting rope.
- Do not change the size of fuses. A qualified electrician should carry out all electrical work.
Part 2 Lifting the Load
In order to get the maximum lifetime out of a hoist, you want to be sure that you are using it correctly. Using the hoist for projects out of the hoist group classification for which it was designed changes the lifetime of the product. Before hoisting a load, be sure to determine a safe and effective path for it to travel to ensure that the load will not collide against objects or people. Also, check that no servicemen or unauthorized persons are on the crane and that the rails and power cables are clear of obstructing objects. Before hoisting, check that the hoisting devices are securely positioned on the bearing surface of the hook and that the safety catch on the hook is closed.
Next, you want to ensure that the load’s mass center is on the center line of the hook forging so that the load does not bend the hook neck. Make sure that the force is applied only to the hook’s bearing surface (the lowest point of the hook) because if force is applied to other parts of the hook it will cause undesired stresses. Forces on ramshorn hooks have to be equal on both bearing surfaces. Before hoisting, check that the load is balanced and safely fastened at the lifting points and also be sure that the load cannot slide, slip or detach itself when suspended.
In addition, you need to confirm that the ropes are perpendicular and that the hoist is positioned perpendicularly above the load to be lifted. A load must not be hoisted or dragged along the ground in a way that causes side pull on the roping unless the hoist is designed and manufactured for this purpose. When using a lifting accessory (sling, belt, etc.), always follow the instructions provided by the lifting accessory manufacturer. Finally, if two cranes are needed to handle a load, a balancing beam must be used to equalize the loading. Combined hoisting with two cranes must be supervised by a foreman knowledgeable about cranes or by a crane specialist who is in charge of the lifting operation.
