Service Life of Cranes

A Brief Explanation of the Basic Terms Classification of Cranes according to FEM 1.001

Prepared by : RAJEEV KUMAR (CEO DCS Crane Div)

RAJEEV

CE FEM 1.001 A4
Two crucial aspects need to be kept in mind when weighing up the options before purchasing material handling equipment, such as a Tower Crane: the maximum handling rates of the crane and its total intended duration of use (service life) Said by Rajeev Kumar (CEO Crane Div) While great importance is attached to the maximum handling rates in the decision to purchase, too little focus is placed on an assessment of the cranes service life. For this reason, the basic interrelationships and factors influencing the service life of a Tower Crane are explained below. 2 What Do we Really Mean by Service Life? When a component or an entire unit, such as a crane, is excessively overloaded, it will fail at once. However, by far the more relevant cause of the damage is failure of the crane due to use beyond its service life. Each individual work cycle of a crane (even if the load lifted is far below the cranes maximum lifting capacity) contributes to component fatigue. If a load is applied often enough, the component fails even if the individual loads alone did not lead to the failure.

The Paper Clip Experiment

Take a paper clip in your hand and try to tear it apart. It will not be possible. However, if you bend it back and forth several times, even a relatively small force is sufficient to break it. As a result of the repeated loading, the useful life of the paper clip is exceeded because, as with most components in technical applications, it was designed for a finite service life that is not based on fatigue endurance. With the help of this simple experiment it is easy to understand that both the intensity of the stress (i.e. how powerfully the paper clip was bent back and forth) and the number of bends (work cycles) are relevant for the time at which the failure occurs. However, how would a paper clip made of thicker wire behave? Experience from everyday life teaches us that it would have lasted longer. Another aspect for evaluating the service life is thus the durability (loading capacity) for which a component has been designed. Two fundamental elements are decisive for evaluating the service life of a component or a crane: the load and the loading capacity. The service life is a result of the interplay of these two components. Effects of Loading The loads acting on a Tower Crane during operation are not constant. A distinction is made between different modes of operation (heavy load operation, variable load operation, etc.), in which very different loads occur (still lifting concrete lifting, empty load full load, etc.).

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It is, therefore, not possible to assume a constant load for the crane. As a result, the standards according to which a crane is designed (e.g. FEM 1.001) define the loading spectrum by means of which an attempt is made to describe the actual load applied to a crane.

Given the same loads, an increase in the crane group by one level (e.g. From A2 to A4) corresponds to a doubling of the expected useful life.

How is a Loading Spectrum Determined?

The standard on which the crane calculation is based, i.e. FEM 1.001, makes it possible to estimate the future loading of a crane and select one of four standardized loading spectra. The standardized load spectrum classes range from Q1 (crane predominantly lifts low loads and only rarely maximum permissible loads) to Q4 (crane frequently lifts loads equal to its maximum lifting capacity). Therefore, the decisive factor for selection of a spectrum class is how frequently a crane has to lift heavy loads (in comparison to the maximum load in the mode of operation examined). Loading capacity While loading is a characteristic of crane operation, the loading capacity is a characteristic of the crane construction. 4 When a crane is designed, a certain crane classification is selected by the manufacturer and the crane is designed according to this classification. FEM 1.001 offers a choice of eight group classifications (A1 to A8). In the example above with the service life of a paper clip, we noted that the thickness of the wire is a determining factor for the service life. In the steel structure of a crane the same applies. To put it in very simplified form: The higher the number of the crane group, the thicker the steel sheet and tubing used and the more robust the crane.

Service Life!
If the loading capacity (crane group) and the expected load (spectrum class) are known, the service life (class of utilization) of the crane can be determined on that basis. According to FEM 1.001, this will give us a class of utilization from U0 to U9 and thus an indication of how many work cycles the crane will manage before the end of its service life is reached. Towards the end of the service life, the probability of failure increases rapidly with further operation. The relationship between the sizes, crane group, spectrum class and service life is illustrated in Below Figure and Table. If we now compare a crane in crane group A4 to a crane in crane group A2 with regard to service life, it is easy to determine on the basis of the diagram how long the useful life of each one will be.

If both cranes are used for the same type of application, the same spectrum class applies to both cranes. If this class is specified as Q3, it can be seen that the crane classified in A4 will have a service life of more than 4,000,000 work cycles whereas the crane classified according to A2 will reach the end of its service life after only 500,000 work cycles. The crane with the higher classification thus has a useful life that is over four times longer given the same loads! As a rule of thumb, one can state on the basis of the diagram in below Figure. Cranes that have been classified in the highest crane group, A8, are designed such that the loads on the components during operation are so low that theoretically no fatigue is caused by such operation. Consequently, a crane classified in crane group A8 does not have a limited service life and will have an unlimited fatigue endurance.

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Our comprehensive service in tower crane runs from initial consultation to dismantling, and encompasses all aspects of crane management advice and site visits to determine exactly which cranes will best suit your requirements.

15 to 40 Meter Range (RBI Series) The RBI Series cranes; a line of cranes of easy erection and simple use, thanks to their handiness. The hydraulic erection is very quick and safe. The Steering axels with minimum radius of curvature allow the RBI cranes to be positioned in narrow spaces. Thanks to the "self ballasting device" the crane can load the ballast by itself without the need of other means. The Simple and reliable mechanisms, controlled by a frequency inverter, give smooth and fast movements, avoiding to overstress the cranes structure. The RBI cranes, thanks to limited weights and dimensions, can be transported on trailers, keeping perfectly within the dimensional limits for road circulation. 30 to 80 Meter Range (TLX Series) The TLX Series; a new line of crane that offers the best present technology. The well proportioned, essential and stylish line, that shows the basic parts of tower cranes, clearly remained that the "flat top" cranes aren't a "revolution" but an "evolution" of the product. The easy and quick erection is the main point that have impressed operators and technicians; it has been achieved a 20% reduction in erection times, compared to previous cranes. 30 to 80 Meter Range (TCK Series) The ideal line of cranes for your building yard. TCK series cranes are designed and manufactured to guarantee the highest safety standards during every assembling and working activity. The hinges coupling to the center plate allow the jib and counter-jib to mesh without dangerous adjustments being required. The lifting, slewing and distribution mechanisms are strong, simple and reliable. The modularity of its components makes it extremely safe and easy to transport, by keeping the required number of means of transport to a strict minimum. 36 to 80 Meter Range (LX Series) These cranes have been designed for work on particularly high buildings or in extremely restricted spaces. The luffing jib cranes are a good example of advanced technology and they are very fast to install. Those cranes are conceived to solve all the problems that may appear in building sites settled in crowded places, in the town centers or in some areas full of obstacles like prefabricated buildings or towers.

FMgru Establish in Yr. 1926 is World leader in producing best in class tower crane. HIGH SAFETY: Safety has always been the main objective of FMgru. Correct crane operation, the highest safety for people and easy inspection are the three aspects on which every safety devices have been developed. The result has allowed us to offer quality construction cranes that complies with the main international directives (ISO, IEC, DIN, CNR, UNI, FEM).

Fmgru construction cranes, based on standard range but normally modified in many ways to suit the particular application and customer requirements, different from case to case, can be easily inserted in both new and already existing industrial plants and operating circles.

STRONG DETAILS : Strong, sturdy and well sized mechanisms allow the structural characteristics of a well defined project to be used in the best possible way. Use of electronic equipment allows the crane driver to perfectly control the load. FMgru engineers are able to design cranes according with your requirements

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