Revolutionizing Cranes and Rigging: Technology & Innovation

Technology and innovation in cranes and rigging is a topic not discussed as often as it should be. Slings, shackles and even the cranes we use still very much function in the same basic ways as they always have. However, it’s worth stepping back and looking at just how much technology and innovation have impacted our industry, as well as what is available now and in the future. 

Crane Type Innovation

Cranes have used mechanical advantage to hoist heavy loads since the Roman Empire and Middle Ages. They were used in the construction of castles and cathedrals and can be described as treadwheel cranes powered by people walking in the large treadwheel.

WWII led to the introduction of hydraulic technology in cranes with a material-handling crawler nicknamed the Anteater. In 1946, the Hydrocrane was released, the first hydraulic crane that resembles the RT crane we see today. It had a telescopic boom that it carried with it and all its functions were fully hydraulic.

Since that time, demand for cranes able to lift larger and larger payloads has been a constant. In response, cranes of all types have gotten larger and larger, but other innovations have allowed for sizable capacity enhancements through an increase in the ability of the crane to resist the moment imposed on the crane when lifting.

Examples of this include ringer cranes, super lift attachments and y-guying. Newer developments in this space prioritize balancing track loadings during lifting through the incorporation of radius adjusting counterweight mechanisms. These cranes minimize the peak track pressures and can help result in lower ground bearing pressures.

Crane Technology Devices

Technology and innovation in cranes come from both manufacturers as well as third parties. This technology has allowed for easier, safer and more efficient operation. 

Controller area setworks (CAN bus) are utilized at the core of crane control systems to allow for the reliable exchange of commands and information interconnected across the crane. The CAN bus takes input from the joysticks or lever and then sends the command over a data network until it reaches the controllers.

The controllers receive information from sensors around the crane, which allows decisions to be made and sent out. The devices across this network are continuing to get more intelligent and autonomous as technology advances.

Pressure transducers or sensors are integrated into today’s cranes and provide information to the operator and crane on items such as emergency stop sensors, load cells, crane level, outrigger loads and positions. This information is critical to providing the operator with the right information at the right time, as well as providing protections for safe operation.

Anti-collision technology has become increasingly popular, especially in tower and overhead cranes. It may use multiple sensors, laser technology or LiDAR. This technology is very impactful, especially on busy job sites with multiple crane booms within reach of one another. Technology in this space is rapidly evolving and goes well beyond tower and overhead cranes.

We have seen similar technology deployed in personal vehicles for around a decade now, and we are now seeing it deployed on all types of construction equipment as we focus more and more on the minimization and elimination of the interface between mobile equipment and personnel on construction sites.

While not the highest tech solutions, cameras are now commonly deployed on cranes to view and monitor any number of items. The operator may have rear-view/tail-swing cameras or camera coverage for their entire range of blind spots to aid safe operation.

They may also have cameras positioned to monitor various functions of their cranes, such as winch cameras. Hook cameras can provide operators with a unique perspective and may eliminate a true blind lift. Software developers have also been able to leverage information obtained from these cameras to learn and develop cycle times of various common lifting operations and ultimately help pinpoint inefficiencies in the cycle from lift to lift.

Telematics data is now commonly available and captured by end users of cranes. Telematics data includes engine hours, fuel usage and much more. We are getting better as an industry at identifying key indicators from this data to allow us to identify systems not operating in a nominal state and opportunities for improvement in the efficiency of our operation.

This can help us to identify leading indicators of potential upcoming problems or to understand important factors, such as idle time. We can also utilize telematics data to help identify and ultimately strategize to address and improve sustainability efforts, especially around emissions and fuel burn. Auxiliary power units are now available on some equipment to allow the cab of the crane to remain climatized without the need to run the main crane engine.

Hybrid and electric cranes are now a reality, and they are helping to drive down greenhouse emissions while maintaining crane performance. I’d expect the technology in these areas to continue to improve and ultimately lead to more cost-effective implementation of this technology in a way that will support the demands of a modern construction site.

The immediate and near future in crane technology likely includes big-ticket items like remote or even autonomous operation. Remote operation is already being piloted, including one example our team observed utilizing a remote operator in the USA controlling a crane halfway around the world in real time. Remote operation would allow for the maximization of operator utilization while simultaneously minimizing carbon emissions, as the crane will only need to be running when actively being operated. Autonomous operation is an entirely new level, but expect to see continued steps towards this capability in the coming years.

Technology and Innovation in Rigging Hardware

Rigging hardware has seen the adoption of innovation and technology, primarily through the adoption and use of synthetic and composite materials. Robotics technology is also beginning to find its way into the rigging industry.

Synthetic materials have long been used in rigging, most commonly in slings. Synthetic web and round slings began using nylon or polyester fibers to carry loads using lighter and more flexible materials than traditional wire rope and steel chain.

Synthetic rope and other rigging hardware built using high modulus polyethylene (HMPE) or Dyneema has become increasingly popular in recent years. You will find synthetic rope slings, synthetic crane ropes, synthetic chain slings and synthetic “soft” shackles built with HMPE. While these products may be more expensive than their counterparts using wire rope or steel, they offer advantages due to their relatively light weight, flexibility and lack of stored energy, to name a few.

In-line load cells and load sensing shackles are available to provide end users with certainty and live feedback showing accurate loadings being imposed along a given line of support. This is particularly useful where load transfer is expected during a lifting operation or in cases where payloads are rigged with indeterminate loading.

A small but impactful advancement are 360-degree chain hoists. The hand chain cover will rotate 360 degrees, allowing loads to be pulled from any direction and operators to stand safely away from the load.

Composite materials have been used for items such as outrigger pads and access mats for some time. They are a sustainable option that typically has greater durability than their wooden counterparts. In recent years, composite materials have been utilized to build larger crane mats for crawler cranes, as well as lifting and spreader beams.

Other Technology Supporting Crane and Rigging

Physical cranes and rigging hardware aren’t the only items that have been and continue to be influenced by innovation and technology. Virtual reality (VR) simulators, drones and lift planning have also made an impact on the industry. 

VR simulators have been developed for a multitude of crane types, including carry decks, rough terrain cranes, crawler cranes, super lifts, towers and overhead cranes. These simulators place an operator in the virtual seat of the cab without exposing people or equipment to damage.

They allow for training, upskilling, as well as operator competency verification. This technology can aid contractors in ensuring that they identify operators that are appropriately qualified for the equipment they are going to be operating.

The presence of drones on construction sites has become more and more widespread. While they may be known for providing site overviews and progress photos or as a survey tool, they are also able to be used around crane work.

They can fly pre-programmed routes to provide an autonomous flight around a crane and produce the photos and/or video required for necessary crane inspections without the need to boom the crane down each time. They can also be used to monitor tight clearances during a lifting operation at elevation or in hard-to-access areas in real time.

Lift planning has long been done utilizing spreadsheets and CAD software. However, we continue to see technological advancements that help make us more efficient and accurate with our planning. We can pull in accurate information from the model of the site to assist with placing and sizing cranes and transporters for a given operation.

When developing detailed drawings, 3D drafting is now an available planning option, which can show increased clarity around critical aspects of a given lift. Existing CAD software can be programmed to insert blocks for entire cranes based on the make, model and configuration at the click of a button. Lift planning software has been developed and is widely used, which can quickly and easily assemble 3D models of a particular crane configuration along with the payload to be lifted, rigging arrangements and even ground bearing pressures (GBP).

Manufacturers have also participated in the advancements of lift planning through programs that will identify outrigger loads, track pressures and, in some cases, have the ability to plan complete lifts for the users. These tools help lift planners gain important accurate information to be able to plan lifts safely.

Additionally, technology can be utilized to support and expedite the lift planning and approval process. You can digitize the request and approval process, which can not only streamline these steps required by many for critical risk lift planning, but it can also collect data in the background to provide metrics on performance. Being able to gather meaningful metrics allows us an opportunity to identify opportunities and implement solutions to improve lift plan deliverables more quickly and accurately.

What’s Next?

While we may not see technology drive foundational in the crane and rigging industry any time soon, I do expect that we continue to see advancements that lead to increased safety, efficiency and sustainability in our near future. Safety aids will continue to advance; big data will allow us to identify efficiency and sustainability opportunities in any number of areas, and there remains a big unknown as to how and where artificial intelligence will be adopted into
the industry. 

Regardless, technology and innovation are an important part of the story for where we are both today and into the future. 

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Todd Harding is the global rigging manager for Bechtel. He also serves and contributes to ASME B30 subcommittees, is a member of the SC&RA Crane & Rigging Group Governing Committee and is a member of NAMA’s Board of Directors.