Stijlbeton nv from Lier is equipping its new production hall with high-performance hoisting equipment from Constructiewerkhuizen Deman nv in Sint-Eloois-Winkel in West Flanders. With this, the specialist in architectural concrete not only has an experienced partner in house, but also high-quality equipment with which it can further increase its production volume and profitability in the coming years.
The new production hall, 35 meters wide and 82 meters long, will be equipped with two overhead cranes with a lifting capacity of 20 tons. Given the planned variety of activities, not all operations will be able to be carried out by these two cranes. Therefore, three wall-mounted overhead cranes were chosen just below the overhead cranes, ideal for three-dimensional work with rectilinear axes of movement. This allows the cranes to run the full length of the building, expanding the accessible floor space.
Wall walk cranes require a higher investment than half-gantry cranes, but offer additional advantages. The main advantage of a wall-mounted gantry crane is that it poses no obstacle at floor level. With a gantry crane, not only is there a rail on the floor, but the leg can also pose a collision risk. Additional safeguards can greatly reduce that risk, but the confinement of space near the rail remains. So the deliberate choice of wall-mounted overhead cranes here reached for the best possible solution.
The challenge with Stijlbeton's specific requirements was in the relatively large arm length combined with a high lifting capacity of 12 meters and 8 tons. The large arm length should ensure that the hall, with its 35-meter span, can be split into three working zones of more than 10 meters in flexibility.
Since the wall-mounted travelling cranes will only handle concrete elements weighing up to 8 tons in the area close to the wall, Deman saw an opportunity to achieve significant savings by using a "3-step-load-limiter. This allows the maximum lifting capacity to vary according to the position where the hoist is located. With the configuration chosen, all of Stijlbeton's requirements could be met. Through the smart feature 'Load Restriction' the crane could be made lighter, with inherent savings on the crane runway, columns and foundations through a reduction in wheel load.
The high lifting speeds of the overhead cranes present potential risks when operated improperly. Therefore, an optional "Shock Load Prevention" was chosen. This ensures that when a load is abruptly picked up, the hoisting speed is reduced until the load is fully lifted. This eliminates abrupt shocks on the crane, which not only prolongs the life of the crane (runway) structure, but also minimizes wear on its mechanical components such as cables, cable drum, geared motor, and so on.
Another Smart Feature, "Load Floating," holds the load in position via motor power for several seconds during a stop without closing the motor brake. This allows for faster and smoother restarts and better control of the lifting motion.
Finally, the production hall will also be equipped with two gantry cranes with a lifting capacity of 20 tons, intended for moving the concrete elements from production to the outside. To safely rotate heavy loads in the air, one of these gantry cranes will be equipped with two hoists and the "Load Turning Hoist" option. This involves adapting one of the hoists to operate at a greater cable angle of up to 15°.
These hoists are conceived for outdoor use and can operate safely in wind speeds up to 6 Beaufort. For safety reasons, the rails for these gantry cranes are fully recessed. Thus, tripping hazards are minimized, as is the hindrance to forklifts or transport trucks when crossing them.