Liebherr, Model 1800 C60, 60 Ton Capacity, w/(2) 200hp DC Hoist Motors, 240/480VDC, 60hz,
3ph, Built 1976, Completely Refurbished in 2012, Approx. 354ft Mast OAH x 264ft Jib OAL, S/N 1275, (Approx Wgt
662,000lbs), Has not been used since reconditioning.
- Refurbishment includes re-rate for operation in minus 30C
temperatures, fall arrest systems, compliance with CSA electrical standards, jib & mast lighting, Ascorel
anti-collision system, heated machine deck enclosure.
Overview: This Liebherr 1800 C60 Tower Crane is a jacking crane. The mentioned Tower Crane has been fully refurbished to comply with all CSA requirements. This crane has been re-rated to operate in - 30°C ambient temperatures.
The 1800 C60 can lift 20ton at 20tonnes with a 66.5m(218’) jib configuration, or 15tonnes with a 79.4m(246’) jib configuration at a 360° radius. Platforms have been designed to assist with pendant install on Counter jib to put workers in a fall free zone. Utilizing a swingstage system on mast will eliminate workers being forced to climb inside of mast sections during install. All work is complete refurbishing this crane and it is ready for service at any time. Safety; When the Liebherr 1800 C60 was being refurbished, Safety was the first consideration; All electrical components refurbished to comply with CSA standards;
The Liebherr 1800C-60 Tower Crane is a free standing Tower Crane that was to be located at Albian Sands, Jack Pine Mine and Muskeg River Mine for the purpose of material handling on a construction site. The Motor platform includes a 400 Hp DC motor assembly consisting of two 200 Hp DC motors wired in series to drive the hoist drum from both ends. The Trolley motor is a 30 Hp DC motor. The turning ring motor assembly consists of three pairs of 240 VDC motors wired in series so that each pair is on a 480 VDC branch circuit. All DC motors are controlled by certified drives that are protected on the AC primary side by appropriate sized certified over current protection. All controllers are located in a purpose built IP55 E-house at the aft end of the counter jib, below the hoist deck.
All equipment is made finger safe. The hoist deck now includes a heated weather enclosure with provisions for ventilation in the summer months in order to maintain equipment at temperatures above -25 deg C. QPS was engaged to actively work with Martin Winziers (Electrical Engineer) of Morrow Equipment to ensure CSA compliancy which has been provided, a final review upon erection and a Dielectric strength test will still need to be completed by QPS for complete CSA compliancy.
To review the QPS report and modification completed the report is available upon request. Platforms to enable safe pendant install; There are two sets of three pendant bars for the counter jib install. Pendant bars are separated, and stored on counter jib with connecting ends overlapping each other to prevent pendants from penetrating into the mast apex during fit up. Pendant install requires workers to utilize a tugger to pull pendants into place, when the connecting ends meet, workers will install a pin and continue pulling pendant into place. In past, this activity would require workers to install connecting pin that connects pendants together by walking on the round lacing bars.
They were also required to walk the length of the counter jib on the lacing bars to operate come a longs to insure pendant remained within the pendant guides located along edges of counter jib during fit-up. Therefore, Morrow has built removable platforms to be set along the counter jib to assist the workers during these activities. These platforms are designed with removable handrails that will allow workers to always be inside of protected area when platforms are removed. .
Fall Arrest systems engineered specially for this crane; We have engaged Arresting You Ltd. To design a fall arrest system that is custom built for the Liebherr 1800 C60 Tower Crane. This system will include drawings, specifications and instructions by a professional engineer as per CSA Z259.16 Design of Active Fall Protection Systems. A drawing will be provided showing the layout of this system, including where it is located on the crane and the complete assembly of all components.
Fall Arrest systems are being designed to accommodate the vertical assent and descent for each mast section. Fall arrest system is also being designed for the length of the Jib. Installation of fall arrest systems along the mast can be done independently; however, fall arrest system provided for the Jib must be installed by a trained ‘Arresting You’ individual to certify accuracy. Lights installed in the Jib to illuminate working areas below; 4 – C4-F2-LL 1000W Metal Halide CSA compliant light fixtures have been installed along the Jib of the 1800 C60 to illuminate the working area below crane radius. There also 4 lights installed on the Mast.
Swingstage capabilities for safe mast section install; During the installation process of the 1800 C60, 4 separate mast panels are required to be assembled together to form one mast section. Mast sections are then bolted to each other during mast assembly. Inner mast sections and remaining components are then installed. However, this activity requires a large crane to raise heavy components in place.
Therefore, to reduce the size of crane required, The 1800 C60 can be assembled in a jacking environment. Two outer mast sections are required with remaining components and then remaining outer mast sections will need to be partially assembled to wrap around inner mast section as the crane is raised to designed elevation. This would require workers to climb on Mast lacing to assemble outer mast pieces. To prevent having workers in high risk environment, scaffolding contractors have been engaged to provide input on the availability of swing stage scaffolding that can operate around a Tower Crane mast to support mast assembly and install.
There are systems available to provide this method and readily available. Ascorel Anti-Collision device The Liebherr 1800 C60 is fitted with an Ascorel MC602 overflying and anti-collision device. This system can detect the angle, weight of load lifted and ground radius of this Crane. This crane is fitted with multiple sensors for each of the measured parameters which are then displayed in the operator’s cabin to keep them informed. The MC602 was designed to prevent cranes from flying over forbidden zones or running into other cranes. As a situation becomes increasingly unsafe, the MC602 will slow down movement while warning the operator of the danger. The movements will be decreased and eventually stopped to avoid a collision with up to 16 other cranes or flying over up to 10 different forbidden zones.
This model is capable utilizing a secondary display available for control and use of system from the bottom of crane. Loads, wind speed, hook height and movement status available in real time. Supervisors can remotely monitor cranes in real time over the internet if required. Re-modifications made to crane: Crane has been re-rated for -30°C ambient temperatures; Red Associates Engineering performed an engineering study on the Liebherr 1800 C60 to provide cold weather load ratings. Determination of the cold weather rating is based on the best available information from the original equipment designer which was provided by Morrow Equipment Company.
The testing of the crane was performed using material samples cut from the crane. These samples were chosen based on the materials used in construction of the crane system and are representative of the grade of material used in the crane. Charpy v-notch impact testing (CVN) was performed on samples taken from a jib section from the crane. Ludwig and Associates performed these tests under the direction of Red Engineering. CVN test samples were machined from threes samples and tested at -30C. Based on results from materials that were tested as per Canadian Structural Steel standard in CSA G40.21, Structural Quality Steels, these specimens met the cold tough classification desired for cold weather operation.
Due to the low number of samples tested, Red Engineering would require the crane be subjected to higher intervals of non-destructive testing and certification that is normally required. An onsite inspection of the crane after handling and transporting would be performed prior to erection of the crane. The crane would then be inspected each six months while it is in operation on the project for one year and results to be monitored for any fatigue created within this period. Upon completion, the unit would be structurally certified and fit for service by Red Associate Engineering Ltd. All samples removed from jib section were replaced and jib section has been re-certified for service.
Heated Machine deck enclosure; Morrow Equipment Company has coordinated a custom manufactured machine room to sustain a minimum 0°C inside room temperature for the Liebherr 1800 C60 Tower crane to operate effectively in Canada to withstand harsh Northern Alberta winter conditions. This machine deck enclosure complies with DIN 1055 wind design velocity of 151KPH with resulting dynamic wind pressure of 23psf (112 kilogram-force/m²) at the machine room height of the crane. Roof snow design load rated for 20psf (98 kilogram-force/m²). Roof design for live load rated for 50psf (244 kilogram- force/m²). Roof and walls are rigid metal insulated panels that maintain an inside temperature of 0°C with outside ambient temperature of -30°C. Heated enclosure is equipped with a forced air heating system to maintain positive pressure and minimum temperature of 0°C.
Machine deck enclosure is designed to be fitted to crane by the inside of machine room, preventing any worker from having to work in a fall arrest environment. Roof hatched have been installed to allow workers to disconnect rigging after machine room is installed. Crane capabilities Product description; 1. History; This crane was originally sold to Kansas Power and Light, and then sold to NORSHIPCO in Newport News, VA for shipbuilding. Morrow purchased the crane from NORSHIPCO when they dismantled it, in 2002. 2. Motors; The Liebherr 1800 C60 is a free standing Tower Crane used primarily for material hoisting on a construction site. The motor platform includes a 400hp DC motor assembly consisting of two 200 motors wired in series to drive the hoist drum from both ends. The turning ring motor assembly consists of three pairs of 240VDC motors wired in series so that each pair is on a 480 VDC circuit. The trolley motor is a 30Hp DC motor. All DC motors are controlled by certified DC drives that are protected on the AC primary side by appropriately sized over current protection. 3. Capabilities; Jib Configurations: The Liebherr 1800 C60 has two jib configurations available.
This crane can be configured with 66.5m(218’) jib, consisting of 6 jib sections. This configuration is capable of lifting 20 tonnes at the tip, at any height, or 60 tonnes within a 25.6m radius of the mast. This configuration requires 6 - 6500kg counterweights for ballast. These counterweights are being rebuilt by Lafarge to replace existing weights. This crane can also be configured with a 79.4m(246’) jib, consisting of 7 jib sections. This configuration is capable of lifting 15 tonnes at the tip, at any height, or 60 tonnes within a 22.9m radius of the mast. This configuration requires 6 - 7950kg counterweights for ballast.
New counterweights for the 79.4m configuration will be required. Mast configurations: The 1800 C60 is a jacking crane that requires a minimum of two outer mast sections. This crane was designed with 8 outer mast sections and three internal mast sections with jacking assembly. There are 7 mast sections purchased to compliment this crane. Two mast sections will provide 32.3m hook height. 7 mast sections will provide an 82.3m hook height. Each outer mast section consists of 4 panels that bolt together to form one 5m² x 10m tall mast section. Internal mast sections are fabricated as one piece. Jacking ability: To reduce the size of assist crane to assemble the 1800 C60,
This tower crane can be assembled using two outer mast sections and the internal mast section configuration. This will create a 38.3m assist crane lifting height to install the jib(54tonnes). Once jib, counterjib and counterweights are installed, the tower crane can jack itself to the mast configuration required. Reducing elevated lifting weights to 11.3tonnes for remaining outer mast sections. Without jacking the crane, the assist crane lifting height would be 98.3m for a 7 outer mast configuration and the lifting weight would equate to 54tonnes for the jib install. During jacking activities, internal mast section is supported by 2 sets of locking outriggers and wedges secure outer mast to the inner mast to fully secure upper crane components. This crane is not supported by hydraulic jacking components as modern tower cranes.
Outer mast sections are assembled in halves and installed to wrap around internal mast section as crane is raised. This technology is a very safe and secure method of tower crane jacking. 1800 C60 (60tonne)tower crane compared to a Demag CC2800 (600tone) crawler crane 1800 C60 Tower crane: 82.3m mast height, 66.5m radius can safely lift 20 tonnes .
This requires no ground compaction, no matting, within a 360° radius and as close to 7m radius around mast. Demag CC2800 Crawler Crane with super lift pkg: 78m boom length, 70m radius can safely lift 40 tonnes. This requires ground compaction, matting and consideration to boom interference with surrounding structures.