As an important loading and unloading equipment in modern ports, factories and other places, the formulation and implementation of the installation and construction plan of the general gantry crane is directly related to the safe operation and operating efficiency of the equipment. With the advancement of technology and the diversification of engineering needs, a scientific and reasonable installation and construction plan is particularly important. The plan aims to ensure that every detail of the crane in the installation process meets the safety standards and technical specifications through refined planning and operation, so as to ensure its stability and reliability in subsequent use. This article will explore the installation and construction plan of the general gantry crane in depth, from the project overview to the various preparations before installation, to the specific installation steps and processes, as well as the implementation of safety measures and the standards for quality acceptance, to fully demonstrate an efficient and safe installation process.
As a large-scale material handling equipment, the general gantry crane plays a vital role in ports, docks, factories and other places. In order to ensure the smooth installation of its installation work and achieve the predetermined performance and safety standards, we have formulated a detailed construction plan. This plan elaborates on the installation process of the general gantry crane, including the installation sequence and precautions of each component. It also stipulates strict technical requirements, including requirements in terms of size, precision, materials, etc. In addition, we have also formulated comprehensive safety management measures, including safety training for operators, safety signs on site, etc. The project goal is to achieve accurate installation of universal gantry cranes and ensure that they can operate stably and meet production needs after being put into use. At the same time, we will also focus on ensuring the safety of operators to ensure that they will not be harmed during work.
Before the installation work starts, a comprehensive survey of the installation site is required to assess the impact of factors such as topography, geological conditions, and spatial layout on the installation of the crane. During the survey, the site environment should be carefully analyzed, and attention should be paid to whether there are obstacles on the site, such as electric poles, trees, etc., as well as whether the ground is flat and whether the bearing capacity meets the requirements. In addition, the wind direction, wind speed and other meteorological conditions on the site should be considered to ensure safety during the installation process. The evaluation results will provide an important basis for subsequent foundation construction and crane assembly.
Before the installation work begins, a professional installation team needs to be formed, and the members should include crane machinery engineers, electrical engineers, safety supervisors, welders, crane operators, etc. These members need to have rich experience and skills to be competent for their respective jobs. At the same time, the responsibilities and tasks of each member should be clarified to ensure that there is a dedicated person in charge of every link in the installation process. Organize team members to conduct safety education and skills training to improve overall safety awareness and technical level.
According to the model and specifications of the crane, prepare the required installation materials and equipment in advance, such as high-strength bolts, welding materials, lifting rigging, power tools, etc. These materials and equipment must meet the relevant standards, be sufficient in quantity and reliable in quality. During the preparation process, strict material and equipment inspections must be carried out to ensure that all materials and equipment meet the requirements to avoid affecting the installation progress due to material shortages or quality problems. At the same time, a sound material and equipment management system must be established to ensure the rational use and storage of materials and equipment.
List of materials and equipment required for installation
| Material/equipment name | Specifications/Model | Quantities | Note |
| Power Tools | _ | _ | Including wrench, drill bit, etc., reliable quality |
| Safety protective equipment | _ | _ | Such as safety helmets, safety belts, protective glasses, etc. |
| Measurement tools | _ | _ | Such as leveling rulers, tape measure, etc., ensure installation accuracy |
| Cleaning tools | _ | _ | Used to clean the installation area and ensure the quality of the connection |
| Other auxiliary materials | _ | _ | Prepare according to specific installation requirements |
Installation team personnel division of labor list
| Position/role | Responsibility description | Number of people |
| Crane Mechanical Engineer | Responsible for crane installation program development, technical guidance and supervision | 1 |
| Electrical engineer | Responsible for the installation, commissioning and testing of electrical systems | 1 |
| Safety Supervisor | Responsible for on-site safety supervision to ensure that the installation process complies with safety specifications | 1 |
| Solderer | Responsible for welding operations to ensure that the quality of welding meets the relevant standards | 2 |
| Crane operator | Responsible for lifting, assembly and commissioning of cranes | 3 |
| Auxiliary workers | Assist all professionals in completing installation tasks, such as handling materials, cleaning the site, etc. | 2 |
Foundation construction is the first step in crane installation, which plays a decisive role in subsequent installation work and the long-term stable operation of the crane. First, according to the design drawings and the actual situation on site, accurately measure and delineate the foundation position to ensure that the foundation position is accurate. Then carry out the foundation excavation work, and the excavation depth must meet the design requirements to ensure the stability and bearing capacity of the underground foundation structure. During the excavation process, if the geological conditions are found to be inconsistent with expectations, timely communication with the design party should be made to adjust the foundation design plan.
The next step is the steel bar binding link. The steel bars are strictly tied according to the design drawings to ensure that the specifications, quantity and layout of the steel bars meet the specifications to enhance the strength and toughness of the foundation. After the steel bar binding is completed, concrete pouring is carried out. Select the appropriate concrete grade and pour in layers according to the design requirements to ensure the density and flatness of the concrete. During the pouring process, arrange a special person to be responsible for vibration to ensure that the concrete is fully dense.
After the pouring is completed, enter the maintenance stage. According to the characteristics of the concrete, take appropriate insulation and moisture retention measures to prevent concrete cracking. Perform strength testing according to design requirements to ensure that the foundation strength meets the standard. Only after the foundation strength meets the requirements can the subsequent crane installation work be carried out.
The assembly of main beam and end beam is one of the core links of crane installation. Before assembly, check the size, shape and surface quality of the main beam and end beam to ensure that each component meets the design requirements. Then pre-assemble and check the matching between the components to ensure the smooth progress of the assembly process.
During the formal assembly, strictly control the assembly accuracy. Use high-precision measuring instruments to detect the straightness and horizontality of the main beam and end beam to ensure that they meet the design standards. For structures connected with high-strength bolts, tighten them strictly according to the specified torque to ensure the safety and stability of the connection. At the same time, pay attention to the installation order and position of each component to avoid stress concentration or structural deformation due to improper installation.
After the assembly is completed, pre-tighten and inspect. Check the connection, dimensional accuracy and surface quality of each component to ensure that the assembly quality meets the requirements. Only after confirming that the assembly quality is correct can the subsequent installation of the lifting mechanism and running mechanism be carried out.
The installation of lifting mechanism and running mechanism is a key step in realizing the function of crane. During the installation process, strictly follow the requirements of design drawings and instructions. First, install the lifting mechanism, pay attention to the installation order and position of each component, and ensure the flexibility and accuracy of the transmission system. Debug and test key components such as motors, reducers, brakes, etc. to ensure that their performance is good and meet the use requirements.
Then install the running mechanism. Also install and connect each component according to the design requirements. Check and debug the running track, drive device, etc. of the running mechanism to ensure that it runs smoothly and accurately. If any problems or abnormal conditions are found during the installation process, they should be handled in time and confirmed to be correct before continuing with subsequent work.
The installation and commissioning of the electrical system is one of the important links in the installation of the crane. First, carry out cable laying work, select the appropriate cable type and specification, and lay and fix the cables according to the design requirements. Then carry out electrical wiring work, and strictly follow the design drawings and electrical schematics for wiring operations. Conduct insulation resistance test and ground resistance test on the wiring to ensure that it meets the standard requirements; debug and test each control circuit and protection circuit to ensure their normal operation; conduct no-load test and load test on the crane to test the reliability and stability of the electrical system and whether the operation of the entire crane meets the design requirements and standards to ensure its safe and reliable operation and meet the use requirements
Establishing a sound safety management system is the basis for enterprises to ensure safe production. Enterprises should formulate detailed and comprehensive safety management systems based on their own actual conditions, clarify the safety responsibilities of leaders at all levels, departments and each employee, and ensure that each safety work has a dedicated person in charge. At the same time, scientific and standardized safety operating procedures should be formulated, and detailed regulations and requirements should be made for each production link, so that employees can strictly follow the procedures to avoid accidents caused by illegal operations. In order to enhance the safety awareness of employees, enterprises should also formulate safety training plans and conduct safety education and skills training for employees on a regular basis. Through training, employees' safety awareness can be improved, and they can also master the necessary safety skills to better deal with various safety risks.
Set up obvious safety warning signs and isolation belts on site to remind non-installation personnel not to enter the operation area. During the installation process, hoisting operations are one of the common operations. In order to ensure the stability and safety of the hoisting process, hoisting operations must be strictly controlled. For high-altitude workers, safety protection must be carried out, such as wearing safety belts and helmets. At the same time, on-site fire prevention, explosion prevention and other safety measures must also be strengthened to ensure safety during the installation process. The implementation of these measures can effectively reduce and prevent the occurrence of various safety accidents, and ensure the safety of personnel and the integrity of equipment.
During the installation process, it is necessary to identify and evaluate the possible risks and formulate corresponding emergency plans. For example, the risks of heavy objects falling and personnel injury that may occur during the lifting process require the preparation of rescue equipment and personnel in advance to ensure rapid response and handling in emergency situations. In addition, it is also very important to strengthen communication and cooperation with relevant departments to ensure timely and effective support in emergency situations. Through the implementation of these measures, various safety accidents can be effectively reduced and prevented, and the safety of personnel and the integrity of equipment can be ensured.
During the installation process of the crane, it is very important to formulate a set of rigorous quality inspection standards. This set of standards should cover all key components and performance indicators of the crane, such as the straightness and horizontality of the main beam and end beam, and the geometric dimensional accuracy of the overall structure. In addition, it is also necessary to strictly test the key parameters related to the working efficiency and safety of the crane, such as the lifting height and running speed. At the same time, follow the relevant international and domestic standards and design requirements to ensure that the installation quality of the crane meets the expected standards.
After the installation of the crane is completed, the debugging and trial operation work shall be carried out. The debugging work shall cover the core components such as the electrical system, transmission system, and braking system. Through professional equipment and technical means, the performance of each component shall be comprehensively tested and adjusted to ensure its stable and reliable operation. No-load and load tests shall be carried out to test the stability and carrying capacity of the crane. During the trial operation, the operating status of the crane shall be closely monitored, any abnormal situation shall be discovered and recorded in time, and corresponding adjustments and treatment measures shall be taken according to the actual situation.
After the debugging and trial operation are completed, an acceptance report shall be written according to the preset installation quality inspection standards. The report shall record the test results of various performance indicators of the crane in detail, conduct in-depth analysis of the problems and deficiencies found, and put forward targeted rectification measures and improvement suggestions. Through strict quality acceptance and debugging, it is aimed to ensure that the installation quality and performance of the crane meet the relevant standards and design requirements, and provide solid guarantee for its subsequent commissioning. In addition, the acceptance report and corrective measures must be submitted to relevant departments and personnel for filing to facilitate subsequent supervision and management.
Installation Quality Acceptance Report Template (Key Inspection Items)
| Serial number | Inspection items | Inspection standards/requirements | Inspection results | Remarks/Rectification measures |
| 1 | Straightness of main beam and end beam | Comply with design drawings and international/domestic standards | _ | If it does not meet the requirements, it needs to be adjusted to the specified range |
| 2 | Levels of main beam and end beam | Level detection, the error does not exceed ±Xmm | _ | If it exceeds the range, level adjustment is required. |
| 3 | Geometric dimensional accuracy of the overall structure | Measure each key size and compare it with the design drawings | _ | If the size does not match, it needs to be marked and corrected |
| 4 | Lifting height | Meet the design requirements, the error does not exceed ±Ymm | _ | If it does not meet, the limit device needs to be adjusted |
| 5 | Running speed | Meet the design requirements, the error does not exceed ±Z% of the design value | _ | If it exceeds the range, check the transmission system and adjust |
| 6 | Electrical system performance | All electrical components are working normally, without abnormal sound or overheating. | _ | If there is any abnormality, the faulty component needs to be checked and replaced. |
| 7 | Drivetrain performance | Smooth transmission, no jamming or abnormal noise, good lubrication | _ | If there is any jamming or abnormal noise, check and repair it. |
| 8 | Braking system performance | The brakes are sensitive and the braking distance meets the design requirements. | _ | If the brake is not good, adjust or replace the brake |
| 9 | No-load test | The crane runs smoothly without abnormal vibration or noise | _ | If there is any abnormality, record it and find out the cause. |
| 10 | Load test | The load-bearing capacity meets the design requirements and the structure has no deformation or damage | _ | If the load-bearing capacity does not meet the requirements, the structure needs to be strengthened or adjusted. |
Installation quality acceptance report template (summary and filing)
| Serial number | Project content | Description/Results | Responsible Person | Filing department/personnel |
| 1 | Acceptance summary | The installation quality of the crane meets the design requirements and its performance is stable and reliable | _ | _ |
| 2 | Problems found and rectification status | (List the specific issues and corrective measures that have been taken) | _ | _ |
| 3 | Subsequent supervision and management suggestions | It is recommended to conduct regular inspection and maintenance to ensure long-term stable operation of the crane. | _ | _ |
| 4 | Acceptance report submission date | __Year__Month__Day | _ | _ |
| 5 | Confirmation by the filing department/personnel (signature/seal) | ___ | _ | Relevant person in charge |
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