P O R T A L C R A N E S Y S T E M S
UPDATE S P R I N G , 2 0 0 4
PORTAL CRANE PORTAL CRANE P&H Portal Crane
Design
SUPPORT TEAM STRUCTURAL ALERT Considerations
The recent failure of the
KoneWood (Andritz) portal • P&H utilizes a robust,
Parts conservative design for
Joey Liverett - crane girder at Langboard
OSB has prompted many portal crane girder struc-
Portal Parts Specialist ture including open "H"
24-hour line: requests for information
about the portal crane girder or "I" beam lower cord
800-633-1136 construction and fabri-
Please have the serial num- design.The girder top cord
failure occurred Saturday, May cated box section or "H"
ber/location of crane/part
number/contact name, 8th, at the Langboard OSB beam upper cord with
phone, fax, and address. plant in Quitman, GA (near reinforced cluster points.
Valdosta), resulting in the Use of this design goes
death of the operator.The back to many of the early
Service & Training crane is approximately 9 Heede cranes sold from
Ronnie Jones years old.This UPDATE issue 1977 to 1982, and most
Service Manager responds to those customer of the P&H portal cranes
KoneWood (Andritz) portal crane failure at
Birmingham, AL Langboard OSB) requests. sold since 1982 when the
(205) 943-5734 Heede organization
(205) 941-3324 Fax became the P&H Portal
24 - hour line: Structural Inspections: What you should know…. Crane Group. The design
(877) 943-5734 allows for easy inspec-
With the recent girder failure on our competitor's crane, a sharp focus has
tion of all critical welds
been placed on structural inspection of the portal cranes in service today.
throughout the life of the
Questions include; How often should we inspect? Who is qualified? What do
crane.This girder design
Nu-Life Rebuilt we do when a defect is found? The following guidelines are aimed at
has a solid history of
answering these questions and more.
Parts/ performance.
Motor Rewinds 1. Cranes operating in a woodyard environment, handling full capacity loads
• The P&H leg to girder
Joey Liverett nearly every lift, require weekly, monthly, quarterly and annual PM inspec-
connection utilizes heavy
Rebuild Coordinator tions to comply with OSHA 1910.179 and ANSI requirements.The annual
vertical main support
(877) or (205) 943-5734 inspection must include a review of the crane structure, looking for obvi-
links and pins, horizontal
ous defects and damage, including inspection of pins, keepers, and bolted
stabilizer links, and a
connections.This level of structural review is included in standard P&H PM
unique diagonal cross link
Product Support see STRUCTURAL INSPECTIONS Page 2 to minimize the stresses
Regional Manager in the leg to girder con-
Réal Soucy FROM THE EDITOR nection. The diagonal
Atlanta, GA cross link design allows
Dear Portal Crane Customer:
678-665-5225 cell PLAN TO ATTEND the girder to move longi-
770-236-9351 office/fax This is the 35th issue of Portal Crane tudinally with trolley
Systems UPDATE which represents another motion while restricting
step in the P&H commitment to serve our cus- 15th ANNUAL side to side movement.
tomers. P&H PORTAL The P&H design is the
We hope this sharing of knowledge and CRANE USERS result of years of experi-
MORE PORTAL experience will help you in your efforts to
INFORMATION MEETING ence and research into
manage your yard efficiently. reducing the stresses
SEPTEMBER
8, 9, 10, 2004 associated with the gird-
www.portalcranes.com Sincerely, er to leg connections,
Gary Otto, Product Manager which included strain
Portal Crane Products and Services
see DESIGN Page 2
DESIGN from page 1 MAINTENANCE TIPS
gauge measurements and extensive mod- IMPROVED LUBE FOR PINS AND GRAPPLE
eling/analysis.
For some time, we have been recommending the use of Molub-Alloy #777-1 for
Over the past 22 years, P&H has further use on structural pins and grapple pins. Several users reported that grapple greasing fre-
enhanced the ruggedness of the leg end quency of up to a week has still provided acceptable bearing and pin life. The grease has
and support pins by increasing diameters excellent adhering quality.
and increasing load bearing areas. In updating our data, we have found that this product is now available from Castrol
Industrial Lubricants, with their phone number 1-800-GEAROIL (432-7645), in Milford,
• The P&H portal crane girder is designed MA. www.castrol.com Their product number remains #777-1.
to use a conventional trolley rail with Tribology Inc.Tech-Lube also offers an equivalent product called T-777 which has a
clipped hold downs.The trolley rail is an tacky-fibrous texture to resist squeezing. They also recommend a newer product called
independent trolley wheel load bearing T-708MG, which they claim extends lube cycles 5 to 1 and is moly/graphite fortified.
member separate from the girder struc- Tribology can be reached at 1-800-569-1757 in Yaphank, NY. www.tribol.com
ture.This conservative design also benefits
the maintenance of the crane rail.
• For over 22 years, P&H crane cabs have STRUCTURAL INSPECTIONS from page 1
been equipped with seat belts as well as inspections and meets OSHA and ANSI requirements for structural inspection.
being equipped with safety bars across all
front and side windows for protection of 2. Portal cranes in particular, are complex structures with many joints and welds.
the operator and visitors in the cab. Based upon the age of the crane, P&H recommends a more detailed structural
Recent cranes also have shoulder harness- inspection, by a trained portal crane structural engineer, be performed on
es. P&H/Heede cranes according to the following guidelines:
• Less than 10 years old: Every 3 years.
• With some cranes now operating for over • 10 to 15 years old: Every 2 years
25 years in log handling portal crane serv- • Over 15 years old: Annually
ice, P&H portal cranes continue to per- • Anytime the crane is subjected to shock loading or impact, or a major defect
form in dozens of round the clock opera- is found.
tions, utilizing long time proven crane
designs. 3. Phase I Inspection: P&H recommends a visual inspection for the first phase of
inspection, performed by a P&H structural engineer. This includes identification of
• While we are not involved with the analy- worn members, structural cracks or crack indications and associated repair proce-
sis of the failure on the Andritz crane, dures, and bolt deficiencies with recommended replacement procedures. A Phase
based on the aforementioned discussions, I inspection is usually adequate to determine that the crane is ready for return to
and the many years of monitoring portal service or to identify what needs to be done to get it there. If something is found
crane design and performance, we are that requires more in-depth inspection or testing, then a Phase II Inspection is rec-
confident that the type of failure that ommended.
occurred at Langboard will not occur on
P&H/Heede designed portal cranes. 4. Phase II Inspections include NDT of suspected or high stress joints or structural
members, possible ultra-sonic testing of pins and bolts, and a special focus on
problems identified in the Phase I Inspection. In some cases, proper analysis of a
problem may require strain gauge stress readings on suspected or repetitive fail-
ure joints/members and possibly modeling the crane structure and performing
finite element analysis. These studies are sometimes necessary to make a final
P&H WHEEL DEAL !!! determination of the root cause of a problem.
Joey Liverett has once again Summary:
"rolled out" some savings offers for All portal and rotating cranes need to be on a planned structural inspection
wheel and sheave assemblies. program, incorporating routine PM inspections and periodic in-depth structural
Get a 15% discount if you buy review. Records should be kept to document problems as they occur, so that repeat
four or more gantry or trolley problems can be dealt with properly. P&H is the market leader in the crane industry
wheel assemblies and has extensive experience with all brands of woodyard cranes. Our portal
(wheel, axle, bearings and bearing crane product support office in Birmingham, AL serves all of North America and has
housings) size range 18" to 24". Get a dedicated staff of portal crane experts to assist you with any problems and to get
a 10% discount if you by four or you running as quickly as possible when you need service. By consulting with your
more lifting beam sheave assemblies P&H service representative, a recommended plan can be customized for your crane
(sheave, shaft, bearings). and application details.
P&H would be pleased to perform your next inspection and/or maintenance on
your crane, to supply you with any parts, components, upgrades or to give additional
training to your operators.
PAGE 2 PORTAL CRANE UPDATE • SPRING 2004
SAFETY BARS SAVE LIVES! CRANE UPGRADES that
For over 22 years, P&H portal cranes have had safety bars across the front and side cab Enhance Structural Integrity
windows, providing injury and fall protection to the cab occupants for sudden stops.
The P&H cab also has a seatbelt with shoulder harness. Some mills have now made seat
belt use mandatory. Up to now, most operators we have observed do not use the Many of the portal crane upgrades and
seatbelt or shoulder harness, although, if used properly, it can also have every day bene- modernizations offered by P&H are aimed
fits of reducing lower back strain and fatigue. It doesn't take an incident like a girder at enhancing the overall structural integrity
failure to justify using a seatbelt or having bars on the windows. We have recorded and useful life of the crane system. In addi-
cases where operators have been thrown against the front window due to hitting the tion to a good PM program and well
end stops at high speed, and visitors in the cab thrown against the front and side win- trained operators, upgrading your crane is
dows in an abrupt move or stop of the crane, where the safety bars on the windows a great way to improve your crane. Here
prevented a fall from the cab window.We highly recommend use of the operator's seat- are some examples:
belt and having safety bars on all the front and side windows in the cab. If you replace 1. Diagonal Links
your seat or windows, make sure seat belts and safety bars remain intact.
2. Swivel equalizer to truck connection
3. Cab setback with additional cab sup-
port wheels
4. Many More . . . call for details.
HURRICANE SEASON UPDATE:
As the hurricane and strong thunder-
storm season approaches, take precautions
to avoid wind damage to your crane.
Keeping your tracks clean, brakes in 100%
condition and your tie-downs ready to go
is the minimum that should be done. P&H
IMPORTANT: Storm brakes are also a plus for protec-
tion. Don’t park your crane with the grap-
Don't forget to register for the next P&H crane user meeting; September 8, 9,
ple anchored in the pile, but rather pull it
10, 2004. Have some friendly discussions about your crane needs with P&H
up to high position, since a lightning strike
and non P&H users.Topics we will focus on include; PM inspection, Structural
could ground through the cables and weld
inspection, Safety issues, Ergonomics, Electric cable reels,Thermit welding, con-
the strands together, thus destroying the
tinuous bus bars, plus more…
wire ropes, or if blown out of position, the
NOT A PORTAL CRANE grapple could drag over equipment causing
damage. Monitor local conditions and be
P&H's Western Canada branch, Kaverit, recently had an accident during start-up of a prepared.
double girder, top-running container handling gantry crane at the Port of Morrow,
Oregon, where a service technician tragically sustained fatal injuries. Some of the
emails and articles written about the accident may have implied that this was a P&H
portal crane. The Port of Morrow crane is not a portal type crane, and the P&H por-
tal crane truss girder design continues to have a solid history of performance and
integrity. The cause of the Port of Morrow, double girder, gantry crane accident is cur-
rently under investigation.
see full size view on website
PORTAL CRANE UPDATE • SPRING 2004 PAGE 3
2004 MORRIS PORTAL CRANE USER MEETING
REPLY FORM
SEPTEMBER 8-9-10, 2004
HOLIDAY INN HOMEWOOD
260 Oxmoor Road
BIRMINGHAM, AL 35209
TEL: (205) 942-2041 - FAX: (205) 290-9309
TOLL FREE: (888) 452-5769
MEETING SCHEDULE
WED, SEP 8, 2004
5:30 P.M. - 7:00 P.M. REGISTRATION / SOCIAL HOUR
THU, SEP 9, 2004
7:30 A.M.-4:30 P.M. MEETING / LUNCH
6:30 P.M.-8:15 P.M. DINNER
FRI, SEP 10, 2004
7:30 A.M.-11:00 A.M. / MEETING - ADJOURN
COMPANY: __________________________________________________________________________________
ADDRESS: ___________________________________________________________________________________
CITY:: _________________________________________ STATE: ___________________ ZIP: ____________
TEL: __________________________________________ FAX: _______________________________________
ATTENDEE NAME(S):
______________________________________________ ___________________________________________
______________________________________________ ___________________________________________
______________________________________________ ___________________________________________
WHAT ISSUES WOULD YOU LIKE ADDRESSED AT THE MEETING?
____________________________________________________________________________________________
____________________________________________________________________________________________
WHAT SAFETY CONCERNS DO YOU HAVE? _____________________________________________________
____________________________________________________________________________________________
PLEASE FAX REPLY FORM TO: BARBARA KILLINGSWORTH
MORRIS MATERIAL HANDLING, 117 Lyon Lane, Birmingham, AL 35211
(FAX: 205-941-3324) (TEL: 800-533-1136 - Ext. 214)
PLEASE BOOK ROOMS DIRECT WITH HOTEL: (TEL:TOLL FREE #888-452-5769 FAX: 205-290-9309)
ROOM RATE: (SINGLE / DOUBLE $72.95) (KING $82.95) RATE GUARANTEED UNTIL AUG. 9, 2004.
AIRPORT TRANSPORTATION PROVIDED BY HOTEL.
PAGE 4 PORTAL CRANE UPDATE • SPRING 2004
Bolted Connection Maintenance DYNAMIC STORM BRAKE UPDATE
P&H dynamic storm brakes have been providing reli-
Many users ask what needs to be maintained on bolted structural connections on able braking service for many years on dozens of
portal cranes and chip stackers.The brakes also pro-
their cranes. Here is a summary of what to look for and how to respond if you have
vide a maintenance function by jacking the crane for
loose, broken or corroded bolts. wheel maintenance and testing.Three (3) new devel-
• Monthly/quarterly and annual PM inspections should include visual inspection of all opments have emerged in the storm brake area:
structural bolts, in particular, the girder splice bolts, but don't forget the leg splice 1. An updated replacement brake assembly is now
bolts. available for older brakes that had the screw type
locking devices.These screw mechanisms were
• If a single bolt is broken or missing, it should be replaced with a knowN quality prone to sticking in the down and locked position,
like bolt and torqued to the prescribed value ASAP. causing delays in release. The new brakes eliminate
this past problem with a more reliable design.
• Never re-torque a loose bolt. Replace it. Use proper torque wrenches and fol-
low procedures for lubrication of the threads. Never use an anti-seize compound 2.The mechanical position switch on the side of the
on the threads. brake has been replaced by a more reliable and
better protected switch inside the powerpack
• If more than one bolt is broken or missing, immediate attention must be directed enclosure. This modification can be made to most
at the joint and possible causes evaluated. Replacement of more than one bolt in a older models to improve reliability.
splice joint requires that a bolt replacement procedure be designed and imple-
3. Many Kranco/KoneWood/Andritz users with the
mented. Simply replacing one by one around the joint is not the proper method. cam type "WINDBASS" storm brake systems have
Replacing with a predetermined pattern and placing the trolley (sometimes with a asked for a replacement brake with greater relia-
load suspended) at a pre-planned position for the joint are usually part of the bility. We now have the answer to that question
plan. with the release of the new Dynamic Storm Brake
Conversion Kit. The new brakes mount in the
• If bolts look corroded, it may be time to replace them using an engineered bolt same space the old brakes occupied, and operate
replacement procedure. in both directions for added braking power. Ask
for details.
• If the crane has been subjected to an unusual shock load, bolt replacement should
be evaluated and considered.
Diagonal Brace Girder
Connection
P&H designed an improved leg-to-girder
connection roughly 10 years ago that uti-
lizes a diagonal link across the girder sus-
pension links on both the fixed and hinged
legs. The result of the addition of the link
is reduced stress and longer structural
life. Older cranes can be converted to
the diagonal links with resulting structural
benefits for the remainder of the life of
the crane.
Malmedie Drum Coupling Maintenance
For those crane owners with a Malmedie drum coupling, regular lubrication and inspec-
tion is required for maximum life and performance. Make sure it is on your monthly PM
checklist. The coupling has a built-in wear indicator for visual inspection and frequent
lubrication keeps wear at a minimum. Lack of lubrication causes rapid wear and possible
failure!
see full size view on website
PORTAL CRANE UPDATE • SPRING 2004 PAGE 5
P&H institute classes
TRAINING UPDATE
Smartorque AFD VG+ & G+ Series 2,
The P&H/Morris Institute offers both in-house and on-site training for electrical, July 13-16, 2004
mechanical, and most control types as well as operator training for all types of cranes. A
simulator has now been developed for overhead crane training, and the Institute utilizes Overhead Crane Mech. Maint.
the latest training technology to add value to your training investment. June 29-July 2, 2004
ADVANCED OPERATING TRAINING
Overhead Crane Inspection
P&H Morris continues to provide advanced operating training for all types of log han-
June 8-11, 2004
dling cranes. References will confirm the outstanding value of this unique product support
July 27-30, 2004
service. Contact Ronnie Jones to find out how advanced operator training can enhance
your woodyard operations. Static Stepless Class
August 3-6, 2004
WWW.PORTALCRANES.COM P&H Portal Crane Web Site Static Stepless Lab
The P&H Portal Crane web page can be www.portalcranes.com August 9-12, 2004
viewed by simply going direct to www.portal-
Call The Institute at 800-821-4006 for
cranes.com. Find the latest in product news, Update newsletter index, all back UPDATE
more information.
issues, product support information, case studies, and a crane modernization shopping list.
WE DO ON-SITE CLASSES TOO!
CWF/TAPPI PORTAL CRANE USER Portal User Group Web Site:
GROUP UPDATE www.craneusers.org
The CWF-TAPPI Log Crane User Group MOTAG SOUTH
2004 meeting was held in Richmond,VA on Mar. 24-26. For a complete meeting agenda
and transcripts of presentations or information on the group, go the group’s website: August 4-5-6, 2004
ww.craneusers.org MOTAG South will hold its summer
session in Atlanta, GA. The meeting
opens with a social hour on Wednesday
evening and generally has attendance
REASONS TO ATTEND THE USER MEETING over 150, with a focus on woodyard and
chipping operations.
There are many reasons for you to attend the user meeting. Here are just a few: MOTAG is short for “Millyard
Operators’ Technical Advancement
• Learn about the latest crane safety issues • See various log stacking methods and Group.” You can register at the meeting
procedures by going directly to the Renaissance
• Get the latest training information
• Meet the portal parts personnel Concourse Hotel by the Atlanta Airport
• Meet Portal service personnel or visit the website at www.motag.org
• Share your problems and solutions with for lots of MOTAG info.
• Learn about crane runways others
• Meet people who do what you do • Learn how ergonomic cab designs help
• Find out about the latest technology productivity 15th ANNUAL
P&H PORTAL PLAN TO
• Talk to the grapple experts from Mack • Get lots of maintenance tips and ideas ATTEND
CRANE USERS
• Learn trouble-shooting techniques • Ask lots of questions/get good answers MEETING
SEPTEMBER 8, 9, 10, 2004
Those who have attended previous meetings either come back or send other mill person-
nel the next year. The meeting is attended by woodyard management, maintenance, plan-
Morris Material Handling, LLC
ing, production, and operator personnel. P&H has service, parts, sales and management
315 West Forest Hill Avenue
personnel present to make your time invested worthwhile.
Oak Creek,WI 53154 USA
Telephone: 262-821-4020
Chuck Stoneman Retires with 40 Years of Service! Facsimile: 262-641-9206
Internet: www.morriscranes.com
I want to take this opportunity to congratulate Chuck Stoneman on his outstanding 40 Gary Otto: Cell: 414-573-8062
plus year career and wish him the best in his retirement. He has certainly earned his gotto@morriscranes.com
retirement with so many years of dedicated service to P&H and the portal crane industry. ® Morris Material Handling, LLC,
I am hoping that after the “glitter” of retirement wears off, we can talk him into doing All rights reseved.
consulting work for P&H to provide advanced operator training for our customers.
PAGE 6 PORTAL CRANE UPDATE • SPRING 2004