2. Setting up Today’s Advanced Cranes Introduction Just because a crane is mobile doesn’t mean you can lift loads anywhere. Where and how you set up a crane can matter just as much to safety as its operating condition. With that in mind, where do you place a crane on a worksite? The obvious answer is where the work needs to be done. Crane operators usually don’t select jobsites. But an operator needs to know where a crane can’t be placed and how the area around the crane affects operations.

3. Properly Setting up Today’s Advanced Cranes  Set-up/Site Conditions –The most important consideration is the ground –The site should have controlled access –The crane’s workzone should be free of hazards and obstructions –the operator must know how weather conditions affect and limit operations

4. Properly Setting up Today’s Advanced Cranes  Crane Work Zone –The area that is within the reach of the boom in a 360 degree radius In all directions both vertically and horizontally –For telescopic booms the work space should be calculated by the maximum length of the boom fully extended –When dealing with above- ground hazards power lines, buildings, and trees, the entire work zone has to be considered. Crane Characteristics When selecting where to place the crane, consider two areas on the crane:When selecting where to place the crane, consider two areas on the crane: If the work zone falls within 20 feet of power lines, OSHA regulations mandate many safety rules (see OSHA 29 CFR 1926.1407 thru 1412 - Power Line Safety)

5. Properly Setting up Today’s Advanced Cranes  Weight Distribution –How is the Weight Distributed to the outriggers (operating with min. boom and with a Maximum Load) 25% each ? While above-ground hazards matter in the crane’s work zone, underground and surface hazards affect the area within and immediately around the crane’s base. That area supports the entire weight of the crane and any load it lifts

6. Properly Setting up Today’s Advanced Cranes  Weight Distribution –Many believe that the crane is heavy enough to keep its center of gravity in its physical center, and each outrigger would handle 25% of the weight. –This Assumption would be Gravely WRONG! Assuming that the crane weighs 60,000 lbs and the its maximum load is 40,000 lbs at a 10 ft. radius, can you determine the percentage of the combined weight of the crane and the load that each corner bears?

7. Properly Setting up Today’s Advanced Cranes  Weight Distribution –The center of gravity is closer to the tipping fulcrum Although in this configuration tipping is unlikely –The two outriggers on the front could bear up to 85% of the weight, –While the back two would handle a combined 15% of the weight Assuming that the crane weighs 60,000 lbs. and the its maximum load is 40,000 lbs. at a 10 ft. radius, can you determine the percentage of the combined weight of the crane and the load that each corner bears?

8. Properly Setting up Today’s Advanced Cranes  Weight Distribution –How is the Weight Distributed to the outriggers (operating with max boom, max radius and with a Maximum Load) –Boom creates additional weight and load This offsets the 38,000 lbs. of load reduction –The crane could still effectively be applying 100,000 lbs. of ground pressure. –Up to 85% of this pressure could be applied to one outrigger. Assume the load shown in the figure to the left was only 2,000 lbs. The crane still weighs 60,000 lbs.? Warning: The calculations here are for example only. Check the crane’s load charts and manufacturer’s documentation for exact percentages and loading.25

9. Properly Setting up Today’s Advanced Cranes  Level Ground –Mobile cranes are designed to be level within 1% (1 foot in 100 feet) One percent of grade is anything less than foot difference in elevation over 100 feet of distance.

10. Properly Setting up Today’s Advanced Cranes  Level Ground –Chart Capacities DO NOT Apply when crane is setup out of level One percent of grade is anything less than foot difference in elevation over 100 feet of distance.

11. Properly Setting up Today’s Advanced Cranes  Level Ground –Crane MUST be level to maintain capacities. –Target type levels are generally mounted inside the cab –To properly check the cranes levelness place a level on the cranes turntable (as close to the boom foot pins as possible).

12. Properly Setting up Today’s Advanced Cranes  Ground Conditions –Must support the entire weight of Crane & Load –Free of Hazards Above & Below Ground –Constructions sites vary widely, look for trouble areas such as; Backfilled Areas Edges of –Excavations –Ditches, and –Gullies Sewer & Water Mains

13. Properly Setting up Today’s Advanced Cranes  Ground Conditions –Identifying trouble spots is crucial for set up as well as: Travel on the job site, and Route of travel –When ground conditions are in doubt: A geotechnical survey may be required A geo engineer (or qualified person) will take core samples to determine the grounds capacity.

14. Properly Setting up Today’s Advanced Cranes  Outrigger Usage –When used correctly outriders provide; Increased stability Increased lifting capacity (over on rubber capacities) –Always setup according to the mfg.’s instructions Use only the configurations allowed by the mfg. One side may NOT be extended with the other side retracted Tires should be off the ground as instructed by the mfg.

15. Properly Setting up Today’s Advanced Cranes  Outrigger Usage –The outrigger floats must rest on a level surface –The outrigger float must be at 90 o to the ground –The outrigger MUST NOT rest on a slope as shown in the example to the left.

16. Properly Setting up Today’s Advanced Cranes  Outrigger Blocking (Matting) –Matting is used to better distribute the cranes weight over a larger surface area. –Matting also reduces the depth which pressure is applied. –When ground stability is uncertain matting must be used.

17. Properly Setting up Today’s Advanced Cranes  Outrigger Blocking (Matting) –When using Matting; No gaps between boards, Entire outrigger float or crawler track must rest on blocking, When more than one layer of matting is used there cannot be gaps between the matting in any layers.

18. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Always follow the Mfg.’s Instructions –Some newer, more advanced cranes may have self-leveling capabilities As well as manual systems –These systems are typically digital and are more accurate Some may be switchable to show levelness in increments of varying degrees (e.g. 1 o, 3 o and 5 o )

19. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Some older cranes needed to be leveled in two directions Over the front (or rear), and Over the Side –Most newer cranes are designed differently (than cranes were 20 to 40 years ago) Increased capacities Lighter, Easier to transport, and Greater roadability. –The trade-off These cranes have greater deflection in the carriers, booms & structural areas.

20. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Bubble Levels Provided in Older Cranes (as well as some newer models) Not always accurate –Most operators keep a carpenters or machinists level to verify accuracy –In extreme cold, the anti-freeze may not be sufficient –In extreme heat, the fluid may expand to the point of leakage, or outside the inner circle

21. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Bubble Levels (Older Cranes) Bubble inside the inner circle, level within 1% –These cranes were generally leveled in two positions Over the rear (or front), and Over the side –To check accuracy place the level as close to boom hoist cylinders as possible Never place level on outrigger beams or carrier deck to check accuracy Place Level Here Never Place Level Here

22. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Digital Leveling Systems Always Follow The Mfg.'s Instructions for set-up & use –Determine Preferred Boom Position –Usually One of Two Positions Generally the Preferred Boom Position –with the Boom Resting in the Boom Rest (Travel Position) Secondary Position –Boom is Raised With Load sitting on the Ground »This position is normally used when the Crane needs to be re- leveled Warning: When re-leveling the crane there can be NO LOAD on the hook, and the crane must be repositioned to the manufacturers recommend position prior to re-leveling!

23. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Digital Leveling Systems Prior to Leveling –Determine Ground Conditions –Lock or Unlock Slewing »Per Mfg. –Proximity to Overhead Powerlines –Extend O/R to Appropriate Position –Attach O/R Floats –Place Matting as Required –Extend O//R Tires clear of Ground

24. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Digital Leveling Systems Digital read out in this example shown in 5° increments Counting back from center –Crane is 10 0 high in the rear Crane would need to be raised in the front or lowered in the rear –Depending on Ground Clearance

25. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Digital Leveling Systems Digital read out in this example shown in 3° increments Counting up from center –Crane is 3 0 high on the front left corner Crane would need the front left corner lowered –Depending on Ground Clearance the other three corners may need to be raised

26. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Digital Leveling Systems Digital read out in this example shown in 1° increments for more accuracy Counting from the center –Crane is 2 0 high on the right side, and –Crane is 3 0 high in the rear Crane would need the rear O/O’s lowered left rear being lowered the most

27. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –Digital Leveling Systems Digital read out in this example shown in 1° increments for more accuracy Crane is shown level and ready for the remainder of the set-up process

28. Properly Setting up Today’s Advanced Cranes  Leveling The Crane –It doesn't matter whether the crane is Old or New, –The most important thing to remember is to make certain your operator(s) are familiar with the particular process developed and required by each manufacture for the particular crane he or she will be operating.