Rubber Tyred Gantry Crane - Site Assembly Procedure

Rubber Tyred Gantry Crane Site Assembly - Man Power Description

• Structural Works
1. Fabricators – Fabricator’s for Structural Plate Cutting and Plate Edge Weld
Preparation.
- Fabricator’s for General Works.
2. Welder’s – Welder’s Pre-Qualified (6G Position) M.A.W. Welding Process – Full
Penetration One (1) Side.
- Welder’s for General Works.
• Mechanical
1. Mechanical – Mechanic’s for Detailed Assembly, Gantry Drives, Mechanical
Systems.
2. Mechanical – Mechanic’s for Basic works including Assembly of Ladders, Access
Ways, Wheel Guards,etc.
• Electrical
1. Electrical – Electrician’s Pre-Qualified for Final Termination Works.
2. Electrical – Electrician’s for Cable Tray Installation and Cable Pulling / Cable Tying.
• Riggers – Experienced Riggers for the Slinging & Lifting Arrangements of the Portal
Structure and Assist with the installation of the balance of the modules for the RTG
Crane
 Cable Chain
Festoon System Trolley & Hoist
Assembly

Head Block Cabin

Assembly

Spreader

Resistor Platform
& Resistors

Gantry Assembly
 Walkway

Bridge Girder

Tie Rod

Access Way
Exhaust
System

LEG
Diesel
Generator
E-Room

Diesel Generator
Sliding and
Folding Access
Platform
Sill Beam
• Picture 1 – Lay out Bridge Girder and
Leg Structures and Level – Align.
• A qualified Structural Surveyor with a
Level Instrument and Theodolyte is
required.
• Measure the Structures and confirm
Alignments and Measure the Leg
Structure to be Cut / Trimmed for the
connection to the Bridge Girder.

Picture 1

• Picture 2 - Cut / Trim / Edge

Preparation of the Leg Structure Joint
to the Bridge Girder. Note that the
Weld Joint Design is Full Penetration
from one (1) Side with Backing Strip. Weld Joint
• After Preparation – Tack up
• Structural Surveyor with a Level
Instrument and Theodolyte to Confirm
Alignments and Measurements.
• Full Penetration Weld Process
Structure Support
• Q.C. NDT – U.T. 100% Stands
Picture 2
• After the welding process is completed, Picture 3
the Weld Joint and surrounding area
must be Painted with the Coating
Specification As per ISO 8501-1 and
by mechanical power tool cleaning.

• Picture 3 – The Leg Connection to the

Sill Beams must be prepared.
• Measurement Joint Preparation and
• Structural Surveyor with a Level
Instrument and Theodolyte to Confirm
Alignments and Measurements.
• Note that the Weld Joint Design is Full
Penetration from one (1) Side with
Backing Strip

6
• After the Structural (Fabrication / Welding / Coating of the Welded Joints) the following items can
be completed.
• Picture 4 (next Slide) –
1. Cable Tray Installation
2. Cable Installation
3. Cable Tray Covers Installation
4. Generator Exhaust Pipe Installation
5. Walkway Grating Installed
6. Crane Signs Painted (These signs are painted where the Lifting Arrangement will not damage the
Signs. In these areas the signs will be completed using a Man Lift)
7. Portal (Bridge Girder) Flood Light Installation including cabling (Photo Below)
8. Final Paint Touch –Up where damage has occurred during installation works

Flood Light
Installation
Picture 4

Walkway Gratings

Exhaust Pipe

Crane Signs
Applied

Cable Trays & Cables Installed

Coating System applied

after welding
• At the same time the Structural Assembly is being prepared the Lower Sill Beam
and Gantry is assembled and aligned.
• First item of this works is to Assemble the Equalizer Beam / Wheel Fork Assembly
to the Sill Beam with the Pin Connection (NCSC will Supply the Equalizer Beam /
Wheel Fork Assembly ). Picture 5 (Next Slide) shows the completed assembly.
• Picture 5 – The following is the preparation procedure for the Sill Beam Assembly
to accept the Upper Portal Assembly Connection:
1. Install Sill Beam / Gantry Assembly to Leveled Support Stands. Again the process
must be done with qualified Structural Surveyor with a Level Instrument and
Theodolyte to Confirm Alignments and Measurements.
2. The two (2) Sill Beam Assemblies (Diesel Side & E-Room Side) must be aligned
centrally and together with the Four (4) corners of the Structure Leveled and
Aligned
3. The Sill Beam Assemblies and also tied with Counter Weight Blocks for Safety
during the Pre-Assembly and Assembly of the Upper Portal Structure (two (2)
Counterweights per side – each Counterweight 10Tons)
4. Backing Strip installed at the Four (4) Upper Portal Connection Areas.
Picture 5

Backing Strip

Equalizer /
Wheel Fork
Assembly Level Support Stands
Counter Weight Blocks
• Picture 6 (Next Slide) – The Upper Portal Assembly - weight includind Access
Ways, Cable Trays and Cables = 31Ton ( 1 Bridge Girder & 2 Legs ) is lifted into
position using the Following Lifting Arrangement (Note also the pre-installation of
the Tie Rods) –
1. 1 x Lifting Spreader Beam – 5T.
2. 2 x Lifting Beams - 0.75T ea x 2 = 1.5T.
3. 2 x Lifting Wire Rope Sling Arrangements ( Each Sling Arrangement Capacity 35T).
4. 1 x 150 T Crawler Crane.
5. 2 x 50T Hydraulic Mobile Crane (to Tail out the Legs during the initial Lift).
• After placing the Upper Structure and Sliding the Legs over the Backing Strip on
the Sill Beam the Structure Alignment must be confirmed by the qualified
Structural Surveyor with a Theodolyte.
• The Upper Portal must be re-strained by wire ropes to counterweight blocks –
tensioning with Chain Blocks. Fixed Points are mounted under the Bridge Girder.
• The Full Penetration Weld Joint Preparation must be Q.C. Inspected and approved.
• After all the above has been completed the Welding Process can be completed
with the N.D.T. 100% U.T. Inspection.
• After the welding process is completed, the Weld Joint and surrounding area must
be Painted with the Coating Specification As per ISO 8501-1 and by mechanical
power tool cleaning.
• Picture 7 (2nd Next Slide) – After the Two (2) Upper Portal Assembles are
installed the Rail Distance (Shown by the Red Arrow) must be confirmed and then
the Tie Rods between the two (2) Assemblies may be connected.
 Picture 6

Lifting Frames

Lifting – Spreader
Beam

Tie
150T Rods
Crawler
Crane Cables From Upper Portal to
Counterweight Blocks

Welding
Process
 Tie Rod
Rail Distance Connection

Picture 7
• Picture 8 – Picture 8
1. Generator Installation – weight 10T
2. Generator Access Platforms Installation
3. Sill Beam Cable Tray Installation
4. Electrical Junction Box Installation
5. Electrical Cable Installation and
Termination

• Picture 9 –
1. E-Room Installation – weight 8T
2. E-Room Access Platforms Installation
3. Sill Beam Cable Tray Installation
4. Electrical Junction Box Installation
5. Electrical Cable Installation and
Termination.
Picture 9
• Picture 10 – Picture 10
1. Install Resistor Bank Platform and
Resistors
2. Install Access Ways and Lighting
Systems

• Picture 11 –
1. Install Gantry Drive Assemblies
(Electric or Chain Drive)
2. Install Wheel Turning and Locking
Assemblies
3. Install Diesel Fule Tank Systems
4. Picture 12 (next page) shows Wheel
Assemblies which will be supplied by
NCSC – to be installed.

Picture 11
• Picture 12 - Wheel Assemblies which
will be supplied by NCSC

Picture 12

• Picture 12 (a) – Install Wheel Guards

and Gantry Drive Protections (noted
with red arrows)

Picture 12 (a)
• Picture 13 – Cabin Assembly –
Supplied by NCSC.

Picture 13

• Picture 14 - Cabin to Trolley

Installation. The Electrical Termination
Works from the Cabin to the Trolley
Junction Box can be completed at the
phase.
• The complete Trolley Assembly is the
lifted onto the Crane Upper Structure
and the Final Electrical / Mechanical
works can be completed – weight 27T
using the 150T Crawler Crane.

Picture 14
• Picture 15 & 16 – Cable Track & Chain
Festoon System installed and
Electrical Termination works
completed.

• Note – After all the Electrical

Termination Works are completed a
Complete Line Check to be done and
the Wiring Diagram is marked up as Picture 15
confirmation.

Picture 16
• Picture 17 – Install Head Block
Assembly (supplied by NCSC) and
Reeve Main Hoist and Anti-Sway Rope
System.

• Pictures 18 & 19 – Typical Cable Tray,

Junction Box and Intercom Installation
works.

Picture 17

Picture 18 Picture 19
 Picture 20

• Picture 20 – After all Structural /

Mechanical / Electrical works
(confirmed by Q.C.) the RTG Crane is
Hand Over to the Commissioning
Team.

• Picture 21 – RTG Cranes ready for

Shipment and loading to Barge Picture 21