How Are Cranes Assembled

How Are Cranes Assembled

Meta Description: Learn how tower cranes are assembled using hydraulic components for upward expansion. Explore the importance, preparation, and steps involved.

This guide will walk through the step-by-step process of assembling a tower crane from start to finish. Key stages like erecting the tower sections, mounting the jib and counterweight, and completing electrical and machinery connections will be examined.

Understanding proper crane assembly methods can help construction crews and operators ensure these tall cranes’ safe and efficient lifting capabilities.

Key Takeaways

• Tower crane assembly is a multi-step process that requires careful planning and mobile cranes to lift components into place.
• Erecting the tower sections securely lays the foundation for the crane structure.
• Ensuring critical parts like the jib, counterweight, slewing gear, and cabin are correctly installed is vital for the crane’s safe operation on construction sites.

Importance Of Assembly of a Crane

Proper assembly of a tower crane is crucial for the overall construction project. Tower cranes are called upon to lift heavy materials and components into tall buildings with relative ease and efficiency.

The crane assembly process requires meticulous planning and complex calculations to ensure each core component is installed correctly and the entire crane structure is perfectly balanced.

During assembly, a mobile crane is often used to position the crane’s tower sections, counter jib, and mast sections. A climbing frame or unit is also utilized to help lift the crane higher as it constructs its structure. Once erected, the crane can then be used to transfer construction materials efficiently using its hoisting power.

Preparations for Assembly of a Crane

Before erecting the tower sections, preparations must be made to safely and effectively assemble the crane. Proper planning is crucial to complete the assembly process while maintaining rigorous safety standards efficiently.

Securing the Work Area

A secure work area is established at the construction site to assemble the crane. The space is cordoned off and marked clearly to restrict access to authorized personnel only. Safety signs are installed to warn workers of overhead operations. If assembling near a busy road, barricades may be required to redirect traffic away.

Assembling the Crane Base

A sturdy concrete foundation or slab is poured to support the weight of the entire crane structure. This concrete base provides a stable, level surface to mount the crane’s own tower and prevent tipping.

A mobile crane is utilized to lift and position the crane’s core components like the mast sections, counterweight, and slewing unit near the base for easy assembly.

Assembly of the Tower Sections

The tower sections form the main structure on which the entire crane is mounted. Correctly assembling these sections is crucial for supporting the crane’s weight crane’s weight and providing a stable base.

• Using a Mobile Crane to Lift Sections: A mobile crane is utilized to lift each mast section into place. Given the heavy weight of the sections, often weighing several tons, a crane with sufficient hoisting power is required. The sections are carefully positioned near the base area for ease of assembly.
• Bolting Tower Sections Together: With the sections in position, construction workers securely bolt each new section to the existing tower. Steel collars and bolted connections join the sections together. As more sections are added, the crane’s tower gradually expands upwards, level by level. Complex calculations ensure the tower structure remains perfectly balanced as it climbs higher on the construction site.

Mounting the Jib and Counterweight

Once erecting the tower, the jib arm and counterweight are vital components. These elements work together to give the crane its lifting capabilities.

• Attaching the Jib Arm: The jib arm, the boom, is mounted to the top of the tower and slewing unit. It extends horizontally, allowing the crane to lift and lower materials across the work site. The jib section requires careful positioning to ensure it functions properly.
• Hanging the Counterweight: A counterweight is hung from the back end of the jib to counterbalance the load. This prevents tipping and allows the crane to lift heavier materials with hoisting power. Workers use a mobile crane to lift and securely fasten the large counter jib and weight into place.

Installing the Slewing Unit & Cabin

Once the tower, jib, and counterweight are in position, the final core components of the slewing unit and operator cabin are lifted into place.

• Connecting the Slewing Gear: The slewing unit contains the machinery that powers the rotation of the upper structure. It is carefully mounted to the top of the tower and bolted securely. Hydraulic connections join the slewing gear to the existing framework.
• Lifting the Cabin into Place: A mobile crane is used to lift the cabin near the top of the tower. The cabin provides the crane operator with an enclosed space to operate the lifting machinery with relative ease and safety. It is then fixed to the jib and slewing unit to complete the crane assembly.

Completing Electrical & Machinery Hookup

With the core crane structure assembled, the final phase involves connecting all electrical and hydraulic systems, which makes the crane fully operational.

• Wiring All Electrical Components: Electricians carefully run cables to connect the cabin controls to the slewing gear, hoisting winches, and safety mechanisms. All electrical wiring is inspected to ensure sturdy connections and compliance with the code.
• Testing the Crane Operations: Once energized, the crane is tested under supervision. Crane operators run through functions like slewing, luffing, and load lifting using weights to simulate materials. These tests verify the crane’s hoisting power and that all movements work safely and as intended. Any issues are addressed before approving use onsite.