Crane Planning and
On-site Assembly

The successful completion of modular-based heavy industrial construction projects is reliant upon safe and efficient crane operations, where the degree of safety and efficiency has a direct impact on project productivity. Corresponding to the design of reliable crane operations, this research proposes 3D visualization-based motion planning for mobile cranes. This approach integrates 3D visualization with mathematical algorithms based on “What if” scenarios, facilitating the design of collision-free mobile crane operations for a large number of lifts in congested areas. The methodology is developed based on two types of interactive analysis: (1) rotation analysis to build 3D visualization for the motions of crane body configurations; and (2) spatial analysis to detect potential collision errors in order to design collision-free crane operations. The rotation analysis is applied for calculating the angles describing the orientations of mechanical elements in the crane system by reading the coordinates of the crane location and pick and set points of the object (module) to be lifted. The spatial analysis, meanwhile, is used to monitor and maintain sufficient clearances between existing obstacles and the crane body configurations in order to prevent potential collisions during crane operation design. The methodology is tested on a case study in order to illustrate its effectiveness.

Modular-based heavy industrial projects, which involve a large number of lifts on congested and/or dynamic site layouts, require not only the design and selection of efficient mobile crane operations, but also rapid and accurate responses to design changes in the planning stage of the project to ensure successful project completion. Existing tools have not yielded strategies which support informed decisions to select the most suitable mobile crane operation (e.g., the cycle time of the crane lift) among several alternatives. This research develops a 3D-based crane evaluation system (3D-CES) which designs, verifies, and simulates 3D visualization of mobile crane operation not only to support the selection of the most efficient crane operation, but also to plan the crane lift schedule during crane lift studies based on identification of safety and productivity aspects. These aspects are shown to increase efficiency, timeliness, and profitability of construction through effective collaboration and communication. As demonstrated in a case study, 3D-CES can permit users to design and select the most suitable crane operation by providing crane digital lift information, even when frequent design changes, such as those to lifting sequences, crane locations, and material pick points, are encountered.

This research involves the development of the Quikmod-2 (QM-2) modular lift frame, which is a redesign of the original US model to comply with Canadian standards. The QM-2 has a 10ʺ pipe at the end of which special eyes are attached that transfer the stress directly to the crane hook. This solution on the upper part of the rigging allows the compressive stress to be concentrated in the pipe between the ears, leaving the ropes attached directly to the lift lugs in a vertical plane. The bending moments in the beams of the frame compensate in one plane and, although the beams are statically indeterminate, the reactions in the ropes can be quite accurately calculated using the global stiffness matrix. The QM-2 lift frame also features windows that can be moved along the main frame beam depending on the center of gravity of the object being lifted. Accompanying the device is full documentation on its use, maintenance, transport, and storage.

This research involves the development of the third-generation Engineered Module Lift Frame (EMLF-3), designed to help diversify the crane rigging configuration options to handle loads up to 240 metric tonnes. The unit can be attached to designed pipe bar lengths ranging from 5 ft to 80 ft to create a spreader bar assembly. The modular concept for the bar allows easy transport between projects as well as compact storage at job sites. The attached legs, meanwhile, elevate the entire assembly above grade to keep its elements clean during inclement weather conditions.

In heavy industrial construction, the on-site approach is being gradually replaced by the off-site (modular-based) construction method, which is faster, better-quality, and more environmentally-friendly. Given this trend, cranes have a considerable effect on successful completion of modular-based construction projects with respect to project productivity and safety. However, lift engineers and project managers face the challenge of designing collision-free crane operations prior to construction commencing. In this context, we introduce a methodology whereby a dynamic graphical description of 3D visualization is applied to simulate various scenarios with different crane models and types in order to select the most effective and efficient crane operation. The case study demonstrates the significant value of 3D visualization, from design to implementation, in the following respects: (1) improving productivity by eliminating uncertainties; (2) facilitating better communication, understanding, collaboration, and decision making; and (3) assisting project practitioners in successfully performing critical lifts during actual construction.

Modular projects in the heavy construction industry are reliant upon the use of high-capacity crawler cranes. Because of the significant increase in the weights of the industrial modules in use today, ensuring proper ground integrity under the crane track is critical to preventing crane collapse. This research thus investigates ground integrity under crawler cranes, beginning with an analysis of the expected pressure under the tracks in order to ascertain the necessary ground treatments. Typically, the ground bearing pressure (GBP) is computed using the fundamentals of statistics at the four edges of the crane (left-front and -rear, right-front and -rear), considering track width under uniform loading. FEA shows that the GBP values deviate even for two corners of the same edge (width-wise). As an alternative to the traditional approach, a novel method is developed in this research that not only calculates GBP at all 8 corners of the crawler tracks, but is also capable of calculating the GBP at any point along the track area. This method is used to establish a comprehensive GBP profile for crawler cranes.

One of the highlights of Dr. Al-Hussein's career came with his recruitment to assist in the construction of a Long Island mansion in New York, US. Encompassing four pavilions and some 22,000 sq ft, the sprawling mansion also incorporated 108 concrete panels weighing in at between 3,000 and 61,000 lb each. Dr. Al-Hussein's recruitment to plan and oversee the crane lifts for these panels has contributed to his growing reputation as a world-class researcher in the area of crane planning and optimization.

This research project devised a methodology to aid practitioners in preparing lift studies with crane selection, positioning, and lift optimization using 3D. The 3D visualization helped to identify collision-free paths and optimize lifting activities based on optimal crane paths, with the cycle time and speed of each crane activity taken into account using simulation. The methodology assisted lift engineers and project manager in selecting the best possible crane. The methodology was applied to the construction of a four-storey, 68-unit residential facility in Westlock, AB, Canada. The IRC research team provided a 3D visualization model to the construction team more than two months in advance of the scheduled on-site assembly, which assisted the contractor in selecting the optimum crane and successfully completing all lifts (30modules, 25 tons each) in just two working days.

Refineries have scheduled downtime from continuous hydrocarbon production during which individual units or entire production plant assemblies are replaced. As a rule, downtime is very limited and individual operations are carefully planned several months or years before the actual stoppage. This research involved the replacement of a 72,000 kg depropanizer situated adjacent to units that were not being replaced and in some cases were still operational in limited production. The entire operation carried out by the industry partner, NCSG Crane & Heavy Haul, was performed exactly as planned and computer-calculated. The presented images show a vertical tank from a refinery, computer simulation analysis, distance tolerances when lifting the device, and the current exchange operation.