METHODOLOGY ERECTION OF TOWER CRANE

I. ERECTION SEQUENCES

1. This erection procedure allows a rapid assemble of the crane until it reaches its telescoping position.
2. It requires an auxiliary mobile crane, the characteristics of which much correspond to the parts to be
handled.
3. Reducing the operating time of the auxiliary crane to the minimum on site involves a good
coordination between the erection and assembling sequences, the erection team and the
appropriate accesses and assembling area.

II. GENERAL INSTRUCTION FOR ERECTION

1. All the handling operations using the mobile crane must carried out safely.
2. Do not overload the mobile crane.
3. Use slings in good order and of correct lengths according to the weights of the parts to be lifted.
4. Pay attention to all the slinging points.
5. Make sure that all the necessary protection and safety means are fitted and used, such as ladder,
platforms, guard-rails, safety belt etc.
6. It is absolutely forbidden to lift a load if the counter jib ballast weight is not fitted.
7. The crane must not be telescoped up with the wind speed exceeding 13 miles/sec.
8. It is essential that regulations on the number of the counter jib ballast weight subject to the jib
lengths are observed strictly

III. PREPARATION OF CONCRETE BLOCK CRANE FOUNDATION

1. Preparation condition – The table of forces and stresses, the dimensional characteristics of the fixing
angle, the fitting of fixing angles to determine a concrete blocks dimensions and reinforcement.
2. How to choose the concrete block – It is permissible ground pressure of the site that determines for
the final height to be reached and for each type of machine, the best type of block to use for tower
crane with any height, choose the block with a ground pressure equal to or lower than that of the
ground site.
3. Dimensional characteristics of the fixing angle – The fixing angles must be fitted symmetrically in
relation to the axes of the block and form a 2 meter square according to the dimension of the mast.

IV. ASSEMBLING THE PARTS OF THE CRANE

1. Assembling the 1.6 x 1.6 x 3m mast section - Fit and fix the mast section panel with 20 mast bolt
and nut, 3m ladder and rest platform with guard rail.
2. Assembling the upper and lower slewing - Fit and fix the upper slewing into lower slewing. Fit
and fix the 2 set slewing reducer with motor. Install the slewing platform and guard rail. Install the
cabin platform and guard rail and fit and fix the operator’s cabin
3. Assembling the cat head ( Tower Head ) – Fit and fix the connecting plate, tie bar using shaft and
split pin. Install ladder back to back using bracket.
4. Assembling the counter jib – Install the side platform and guard rail. Fit and fix the hoist winch
motor and electric panel box. Assembling jib suspending beam for maintenance and service.
5. Assembling the jib – Prepare brackets with 1 meter height and 1.3 minimum wide. Place the jib
assembly at the top and connect each one up to required length of boom using shafts and split pins
then place the trolley to the jib and push it to the foot of jib No. 1. Connect the trolley motor with the
trolley winch. Reeve the trolley rope and tighten it. Place the trolley at the root of the jib No. 1 and
the front rope on the trolley winch should not less than 3 rounds. Install the service platform and
guard rail for trolley winch service on the jib. Connect the tie bar according to the total length of the
jib required.

V. ERECTION

1. Fixing angle - Fit and fix the fixing angle and tighten together with the embedded j-bolt and torque in
accordance to the diameter of the shaft.
2. Base mast (Special Mast 1.5m) – Fit and connect to fixing angle with the 8 – 65mm diameter shaft
pin with lock pins. Check the horizontal and vertical alignment.
3. Mast section 1.6x1.6x3m – Connect the mast section up to the required height using 55mm
diameter shaft pin with lock pins.
4. Monoblock 1.6x1.6x3m – insert the monoblock according to sequence intended for internal
climbing.
5. Slewing assembly – Fit and connects to the last mast section using 8-50mm diameter shaft pin with
lock pins.
6. Tower head assembly – Fit and connect to the upper slewing.
7. Fitting the counter jib – Before slinging the counter jib, first lift the counter jib off the ground about
1meter and correct the slinging points for balance if necessary. Connect the counter jib to the cab
mast by means of 90mm diameter shaft pins and lock pins.
8. Fitting the counter weight ballast – Fix one (1) concrete ballast according to sequence as counter
balance before connecting the full length of jib assembly.
9. Fitting the Jib – Raise the jib from the ground and check its stability and horizontal level. Make the
jib appreciably tilt. Sling and raise it until it reaches the pinning points, and connect it with the cat
head. Pin connect the jib to the tower head and insert split pins to lock it.
10. Fitting the tie bars of the counter jib – Fit the tie bars of the counter jib after fitting of the tie bars of
jib is over. Keeps the mobile crane slinging the jib at the same time without releasing. Pin-connect
the tie bar already moved to the counter jib foot with the tie bar on the tower head using 60mm
diameter shaft pin and lock pins.
11. Fitting the counter weight ballast – Fit the remaining counter weight ballast one by one according
to the various length of the jib after the accomplishment of crane erection. Pin it by using 50mm
diameter shafts. As soon as all the blocks are fitted, they must be locked together using the locking
plate bar. Rope reeving for the hoist winch together with the lifting block.
VI. COMMISSIONING OF UNIT

1. Install all platform and safety rail.

2. Prepare power supply – 440 v, 60 Hz
3. Installation of riser cable.
4. Testing controls and motors.
5. Calibrations of all limit switches.
6. Load testing with the third party involved for certifying the unit.
7. Hand-over the unit with complete certificate ready for operation.

THE SAFETY RULES OF THE CRANE

I. The regulation of the correct used.

1. It is not to use crane until it finished the test.

2. According to the specified of the technology and the method of use, it must be the crane in its good
condition, pay more attention to the safety to prevent the dangerous! To eliminating all kinds of
malfunctions which could cause the safety accident immediately.
3. Operate the crane in the specified cope of temperatures.
4. Abide the specified in the instruction, examine, repair and maintenance.

II. Safety Measures.

1. Read and understand the operation and service manual rules before operation.
2. The operator should always remember all kinds of safety measures and recognize the fatalness and
the operation rules should visible.
3. Forbid the crane operator to get long hair, wears the robe and wear the jewelry.
4. Crane operator should used to read the warning board about safety and dangerous.
5. Stop the operation and report immediately to the concern personnel if the crane encountered
abnormalities.
6. Do not change or add any parts unless manufacture agreed.
7. Examine and repair, lubricate and debug the crane in accordance with the cycle that specified in the
instruction manual.
8. The crane operator should be aware of the position of the fireproofing equipments and its usage.

III. The qualification of the personnel.

1. It must be qualified personnel to operate the tower crane.

2. Crane operator must be trained. Ability of operator, rigger, erector and maintenance persons should
regulate definitely.
3. Crane operator should clear their responsibilities and make him know that he should reject all the
orders which against the safety.
4. Experienced personnel must supervise at job site when the tower crane operating by trainees and
learners.
5. Installation, adjustment and maintenance for electrical must be operating by capable electrician.
6. Adjustment and maintenance for traveling mechanism brake system and trolley system must be
carried out by professional.
7. Installation, adjustment and maintenance for hydraulic system carried out only by professional.

IV. The safety rules during working stage.

1. Before each starting check the order from the work principal. Switch on, got rid of fill block, loosen
the device or other fixing device ( wind power <13m/s ). Check that there is no obstacle on the track.
Check all the protection and safety devices whether in normal condition.
2. Operating the crane should in the cab or on navigation stage.
3. Testing the action of every mechanism weather normalization with no load and low speed.
4. Prohibit all possibility operate mode to threaten safety.
5. Forbid the load pass over the person when operating the tower crane.
6. Somebody should present when the load out of the sight line.
7. Do not sling the overweight load out of the specified radius.
8. Do not canting pull the load.
9. Do not sling the load fixing the ground.
10. Do not stop the ordinary action when emergency stop button, it can use only in exception condition
which threaten the safety.
11. Do not use the limiter and brake as normal stop device.
12. Do not make safety device short circuit, change the adjustment or obstruct normal working.
13. The load should be inferior to 1 square meter per ton or maximum wind allowed wind speed <20m/s.
Stop working when wind reached20m/s.
14. Work ending, raise the hook below the limit point and forbid leave the load in the hook.
15. Parked the trolley closer to the mast when operation ends.

METHODOLOGY DISMANTLING THE TOWER CRANE

As far as dismantlement of tower crane is concerned, it can be carried out completely by means
of mobile crane. If the site conditions permits, it can be carried out partly by the hoist winch, which
requires the electrical installations to keep untouched.
Given the capacity of the mobile crane cannot meet requirement, the dismantling of the jib can fall
into two phases:
a. Sling the jib nose and unpin the tie bar, then lower the jib nose to the ground.
b. Sling the jib foot, and lay the whole jib to the ground.
 For INTERNAL CLIMBING set up, it can be carried out completely by means of DERRECK CRANE.
This kind of tower crane is designed especially for the dismantling of internal climbing tower crane. It
is installed in the roof of the building directly since it has no mast section at all. It is safe and reliable
while dismantling the internal climbing tower crane.
For certain component dismantled, such as jib, counter jib, etc., it is necessary to comply with
regulations so as to prevent the rest of the crane from losing its balance as the component is
removed for safety purposes.

I. PREPARATION BEFORE DISMANTLING OF TOWER CRANE

External Set Up:

a. Make sure that no obstacle blocks the dismantling operation.

b. Connect the cathead or tower head access ladder properly.
c. Raise the telescopic cage to the top of the mast tower and pin-connect it at the four corners.
d. Fit the telescoping accessories, considering the following points;
a. Extend the cylinder completely and pin-connect the telescoping lugs.
b. Raise the mast lifter into the monorail and fix it on the mast section to be dismantled. Slew the jib to
the open telescopic cage side.

Internal Climbing Set Up:

a. Make sure that no obstacle blocks the dismantling operation.

b. Preparation of authorize manpower or erector group, tools and equipment required.

c. Drilling of slab in the location of the Derrick Crane Cross beam position at (3’’dia.) Three inches
hole diameter.
d. Used the tower crane for lifting of derrick crane part and components on the top of building were we
place the derrick crane.
e. Start Erection of Derrick Crane and its accessories by used of tower crane.
f. Connect tower crane cylinder together the yoke or climbing beam to the collar beam wherein
presently sitting and lock preparation for jacking down.
g. Fix another set of collar beam wherein previously located preparation for jacking down to hold and
sit. Make it sure shoring component connected to hold the equivalent dead load for safety.
h. Jacking down the tower crane and fix.

II. DISMANTLING SEQUENCE – EXTERNAL SET UP

a. Carried out the telescoping sequence but in the reverse procedure. In order to dismantle mast
section, the telescoping cycle must be repeated. It is necessary to put the safety wedges in the
support shoes when telescoping.

b. On requirement, repeat the operation above mentioned as many times as possible until the mast
tower is dismantled completely.

c. Disconnect the cylinder then put it down safely.

d. Pin-connect the lower slewing to the basic mast with shafts normally used for work. Remove the
telescoping accessories (such as hydraulic parts, mast lifter and so on).

|||. DISMANTLING THE WIRE ROPE AND COUTER JIB BALLAST

a. Lower the pulley block to the ground.

b. Unpin the rope anchor box from the jib nose swivel.
c. Remove the counter jib ballast until one block of the counter jib ballast remains served as balancer
for the boom.

d. Drive the trolley carriage to the jib foot. Unpin the front and rear ropes after having fixed the trolley on
the jib. Wind the rear rope around the trolley drum and remove the front rope.
e. Disconnect the electric circuits and remove the wire.

IV. DISMANTLING THE JIB / BOOM

a. Dismantle the tie bars of the jib or boom by means of hoist winch or alternative tools that can carry
out to lowered and remove connections.
b. On the sling point, sling and raise the jib by means of two wire ropes at least 8 meters in length.
c. Make sure that the brackets used for supporting the tie bar are in proper position. Raise the jib or
boom slightly so as to release the tie bar.
d. Loosen the wire rope by means of the hoist winch or alternative tools until lower and upper tie bar are
lowered to the brackets on the upper member of the jib.
e. Sling and lower the jib to the ground.
f. Remove the last counter jib ballast on the counter jib.

V. DISMANTLING THE COUNTER JIB

a. Disconnect the electric supply circuit to the hoist winch and then remove the cables.
b. Dismantling the hoist winch. To be chosen by actual condition.
c. Fasten the counter jib with at least 8 meters sling folded in half or with two 4 meters sling for slinging
the counter jib.
 d. Lift the counter jib up slightly to slacken the tie bar.
e. Unpin the tie bar from the twin link of the cat head or tower head.
f. Remove the shafts and place the tie bar on the counter jib.
g. Sling and remove the access from the counter jib to the top of the tower crane.
h. Unpin the counter jib and lower it to the ground.

VI. DISMANTLING OPERATORS CABIN, CAT HEAD / TOWER HEAD, SLEWING / RING GEAR
AND MAST SECTION.

a. Check the adjoining assembly and make sure that the electric cable must be disconnected.
b. Dismantle the operator’s cabin
c. Dismantle the cathead / tower head
d. Dismantle the Ring Gear
e. Dismantle all the mast section
f. Dismantle the base mast, including climbing collar, i-beam collar and whole components of the crane.
g. At this time installation of jib pole used for dismantle of derrick crane.

VI. DISMANTLING OF DERRICK CRANE

a. Installation jib pole used of derrick crane.

b. Dismantle jib of derrick crane.
c. Dismantle Ring Gear and cross beam of derrick crane.
d. At this time dismantle jib pole until the last components of the equipment used for dismantle of tower
crane successfully down at the ground level.