As a leading tower crane manufacturer, UNIQUEMAC understands that proper installation is the cornerstone of safety, stability, and optimal performance on any construction site. The process of erecting these engineering marvels is a complex, meticulously planned operation requiring expertise, precision, and the highest safety standards. This comprehensive guide outlines the critical phases of professional tower crane installation, reflecting UNIQUEMAC's commitment to excellence from the ground up.

Meticulous Pre-Installation Planning and Foundation Work

Success in tower crane installation is determined long before the first component is lifted. Thorough preparation is non-negotiable.

• Comprehensive Site Assessment and Planning:
  A detailed site-specific erection plan is the first and most crucial step. UNIQUEMAC provides extensive support documentation, but a certified engineer must assess the site conditions. This includes evaluating:

  Based on this assessment, a detailed Method Statement and Risk Assessment are developed, outlining every step of the procedure, crew roles, and emergency protocols.

  • Soil Bearing Capacity: Geotechnical reports are essential to determine the ground's ability to support the immense loads and overturning moments.

  • Obstacles: Proximity to power lines, adjacent buildings, and site boundaries must be mapped.

  • Load Requirements: The project's maximum lifting capacity, reach, and height requirements dictate the crane model and configuration.

  • Assembly Area: Ensuring there is adequate, firm, and level space for assembling crane components before lifting.

• Robust Foundation Construction:
  The foundation is the literal and figurative base of the crane's stability. UNIQUEMAC cranes typically use one of two foundation types:

  Precision in placing anchor bolts is critical, as any deviation can cause significant issues during the initial assembly phase. The concrete must cure completely to achieve its designed strength before installation begins.

  • Fixed Foundation (Mass Concrete Base): A large reinforced concrete block is cast, often with custom-designed embedded anchor bolts or a base frame supplied by UNIQUEMAC. The design ensures it can resist the crane's maximum overturning moment and compressive loads.

  • Slab Foundation with Ballast: For some models, a concrete slab is used in conjunction with large concrete counterweights to provide stability. This is common for smaller or stationary cranes.

• Crew and Equipment Mobilization:
  Only certified and experienced personnel should perform the installation. The team typically includes a certified installation supervisor, riggers, signalers, and a crane operator. A mobile crane (such as a large-capacity truck or crawler crane) with adequate reach and capacity is selected to handle the tower crane's heaviest components.

 

 

The Sequential Erection Process

The physical assembly is a sequential process where each step builds upon the last with unwavering precision.

• Base Section Installation:
  The first tower section, or base section, is carefully positioned and secured onto the foundation's anchor bolts. Using a transit or laser level, the crew ensures it is perfectly level and plumb. This step is fundamental; any inaccuracy here will be magnified as the crane grows taller. The anchor nuts are torqued to UNIQUEMAC's specified values.

• Tower Mast Assembly:
  Subsequent standard sections (or mast sections) are stacked vertically to build the crane's height. The mobile crane lifts each section, and trained riggers connect them using high-tensile pins or bolts. Each connection must be secure and verified before proceeding to the next. For initial height, several sections are added to provide a stable base for the upcoming components.

• Erection of the Slewing Unit and Operator's Cab:
  The slewing unit—comprising the slewing ring, gears, and motors—is lifted and mounted onto the top of the mast. This complex assembly enables the upper part of the crane to rotate 360 degrees. The operator's cab is then installed, providing the driver with a clear view of the site and housing the primary controls.

• Jib (Boom) and Counter-Jib Assembly:
  This is a critical balancing act. The counter-jib (or counter-boom) is installed first. Then, the main jib, which can be a flat-top or luffing jib design depending on the UNIQUEMAC model, is lifted into place. These components are connected to the slewing unit via large, robust pins.

• Placement of Counterweights:
  Pre-cast concrete counterweights are meticulously placed on the rear of the counter-jib. The number and weight of these blocks are precisely calculated according to the crane's load chart to counterbalance the maximum load on the main jib.

The Climbing Process (Self-Erection)

A key feature of modern tower cranes is their ability to "grow" or "climb" to greater heights, a process known as telescoping or self-erection. UNIQUEMAC's climbing systems are engineered for safety and reliability.

• Climbing Frame Installation:
  A hydraulic climbing frame (or jacking system) is assembled around the top of the existing mast.

• The Climbing Cycle:

  1. Engage and Lift: The hydraulic system engages, and the entire upper structure of the crane (slewing unit, jib, counter-jib) is raised slightly. This creates a space equivalent to one mast section's height within the climbing frame.

  2. Introduce New Section: A new mast section is lifted by the crane itself (or the auxiliary crane) and is maneuvered into the gap.

  3. Integrate and Secure: The new section is bolted or pinned to the existing mast structure.

  4. Reset System: The climbing frame disengages and is repositioned for the next cycle.

This process is repeated until the crane reaches its final working height. Throughout this operation, the crane's load chart is strictly adhered to, and all loads are kept well within safe limits.

 

 

Final Commissioning, Testing, and Certification

Before a UNIQUEMAC tower crane is handed over to the project, it undergoes a rigorous final validation process.

• Functional Tests: All crane functions are tested without load—hoisting, slewing, and trolleying—to ensure smooth operation.

• Safety Device Calibration: This is paramount. All limit switches and overload protection devices are tested and calibrated:

  • Moment Limiter: Prevents the crane from lifting loads that exceed its rated capacity at any given radius.

  • Load Limiters: Prevent over-hoisting.

  • Trolley Limiters: Prevent the trolley from traveling beyond the safe ends of the jib.

  • Slewing Limiters: Restrict the rotation range if necessary.

• Load Testing: The crane is subjected to both static and dynamic load tests. Typically, a test load of 125% of the maximum rated capacity is applied to verify structural integrity and stability under extreme conditions.

• Documentation and Handover: Once all tests are successfully completed, a comprehensive certification dossier is compiled. This includes inspection reports, load test certificates, and compliance documents. Only after final approval by a certified inspector is the crane cleared for operational use.

Why Choose UNIQUEMAC for Your Tower Crane Needs?

At UNIQUEMAC, we don't just manufacture cranes; we deliver integrated lifting solutions. Our cranes are designed with intuitive and safe erection sequences, supported by detailed manuals and accessible technical support for our global clients. By prioritizing robust engineering and clear procedures, we empower your teams to achieve safe, efficient, and productive installations every time.

For your next project, partner with a manufacturer that elevates safety and performance from the foundation to the final lift. Choose UNIQUEMAC.