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DESIGN AND DEVELOPMENT OF HANGING MECHANISM DURING CONCRETE

WELL CONSTRUCTION PART 2

Technical Report · January 2016

DOI: 10.13140/RG.2.1.1291.7845

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

DESIGN AND DEVELOPMENT OF HANGING MECHANISM DURING

CONCRETE WELL CONSTRUCTION PART 2

M. Syarifuddin* .K.F. Seow, F.C. Ang, M. Arif, F. Haziq

Faculty of Mechanical Engineering, Universiti Malaysia Pahang,

26600 Pekan, Pahang, Malaysia,
Phone:+0197626406
*Email: [email protected]

ABSTRACT

This project is to design and develop of hanging mechanism during concrete well
construction. Nowadays, gantry crane is crucial in the development of new and improved
cost-saving applications. This paper covers the design and development of a portable gantry
hoist with a custom frame design for concrete well construction. The design was based off of
the materials that were available and practical for this project to save money. A static and
dynamic analysis will also be performed to study the behaviour of the crane when being used
to hoist heavy object. Throughout this paper, step by step fabrication and material selection
will be discussed. Upon fabrication, the strength of the structure will be calculated and the
result will be compared with those calculated in NASTRAN SOL101 and NASTRAN
SOL103. The safety margin is expected to achieve 3. The common well concrete material is
weigh at 140kg. However, the structure is proven to be able to hoist the well concrete
material up to 200kg after considering the structure imperfection.

Keywords: Gantry crane; well construction; design; development

INTRODUCTION

The cranes have found many uses since the beginning of the history, and the history
of cranes has come across since then. The Greek were the first people to use cranes for doing
the lifting jobs. After this many other peoples like the Roman, the Chinese etc used the cranes
and made many changes to the existing design of that time [1].The crane for lifting heavy
loads was invented by the Ancient Greeks in the late 6th century BC. The archaeological
record shows that no later than 515 BC distinctive cuttings for both lifting tongs and irons
begin to appear on stone blocks of Greek temples. Since these holes point at the use of a
lifting device, and since they are to be found either above the center of gravity of the block,
or in pairs equidistant from a point over the center of gravity, they are regarded by
archaeologists as the positive evidence required for the existence of the crane [2].In modern
industrial system, shipyard, warehouse, and construction, tower cranes are widely used for
the heavy loads transfer[3]. A crane is a type of machine, generally equipped with a hoist,
wire ropes or chains, and sheaves, that can be used both to lift and lower materials and to
move them horizontally[4]. It is mainly used for lifting heavy things and transporting them to

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

other places. It uses one or more simple machines to create mechanical advantage and thus
move loads beyond the normal capability of a man [5].
Cranes are commonly employed in the transport industry for the loading and
unloading of freight, in the construction industry for the movement of materials and in the
manufacturing. Here, The cranes use open loop system to control position while anti-swing
control is done manually by skilled operators using joysticks with analog control [6].A
communication link transmits the remote control signals to the crane-carried control, and
transmits the status information to the remote control [7].The most important substance used
to manufacture cranes is steel. Steel is an alloy of iron and a small amount of carbon. For
structures that do not require very high strength, a common form of steel known as carbon
steel is used. By definition, carbon steel contains less than 2% of elements other than iron and
carbon. Carbon steel exists in a wide variety of forms such as low carbon steel with carbon
content of 0.05-0.30%[8], medium carbon steel with approximately 0.3–0.6% carbon content.
Balances ductility[9] and strength and has good wear resistance. The most important factor in
determining the properties of carbon steel is the amount of carbon present, which ranges from
less than 0.015% to more than 0.5%[10].
Material handling is the movement, storage, control and protection of materials, goods
and products throughout the process of manufacturing, distribution, consumption and
disposal. Material handling involves short-distance movement within the confines of a
building or between a building and a transportation vehicle [11]. It utilizes a wide range of
manual, semi-automated, and automated equipment and includes consideration of the
protection, storage, and control of materials throughout their manufacturing, warehousing,
distribution, consumption, and disposal[12].The focus is on the methods, mechanical
equipment, systems and related controls used to achieve these functions. Gantry cranes are an
important part of the material handling equipment.
The gantry cranes used in the industry are efficient but they only have the ability to
lift the load and put it down at some other position. In this general design, the arm of the
crane moves in the vertical plane only, for example it has constrained motion. The aim of our
project is to re-design the gantry crane.

Figure 1: Basic “A” frame gantry crane[13].

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

This design shown in figure 1 is relatively easy to assemble while it is lying down but
would most likely require two people to stand up. Using two people to stand up the hoist after
assembly seems to be an unavoidable factor in the design.

The Rose Float gantry hoist with 3 ton capacity has a different top beam compared to
figure 1. However, after looking at the frame it was easy to see that the legs were designed
poorly. They were built with rectangular tube which is strong but the “A” frame design
means the legs will start deflect due to the resolving bending moment and the rectangular
tube was oriented to bend about its weaker axis seen in Figure 2. This also allows for
someone to be underneath the frame when it could potentially fail making it a severe safety
hazard.

Figure 2: Rose Float “A” frame gantry hoist

The hoist beam is an S15X42.9 and spans around 26ft without support of the
compression flange making its Lb value 26ft as shown in Figure 3. Adding support (drawn in
Figure 3) would reduce the travel of the trolley slightly but would improve the overall safety
of the design by reducing the beam’s Lb value.

Figure 3: Rose Float gantry hoist, no support of the compression flange

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

DESIGN ITERATION

Figure 4: First design with hydraulic system.

Several designs were proposed by each group member before deciding which is the
most practical design. Figure 4 shows the first design proposed that is equipped with
hydraulic system and the design is basically based-off an engine hoist

Figure 5: Second design uses pulley system.

The second proposed design uses pulley system as lifting mechanism instead of using
hydraulic system as in the first design. This design cost lesser compared to first design

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

because pulleys are cheaper than hydraulic. Design has to be chosen carefully due to budget
constraint.

Figure 6: Third design used available material.

The third design which is also our chosen design were improved from second design
by adding plate gussets on the top beam for better stability during hoisting of concrete well
materials. Wheels were also added on the base so that it is portable and easy to carry. This
design is the most feasible among the proposed design because it is low in cost and easy to
use.

METHODOLOGY

The design was based on of previously built gantry crane. We would like to avoid
especially the “A” frame section used for the supports. The material used was based on what
was available and what would be a strong but not overkill to avoid adding too much weight
on the wheel. In this project we used mild steel obtained from FKM store. A basic design was
made first to get an idea of how much metal was needed and what materials were available to
be used to build the gantry crane. A few rough dimensions were estimated such as the wheel
height, which varies based on wheel material, and overall height of the crane. Once a basic
design was drawn up and the available material was evaluated, the design was drawn in
SolidWorks and assembled. From the SolidWorks models of each part the dimensions were
drawn out and each part drawing was used for a cut list.. However in our project, our major
fabrication will be the body frame and the pulley system used for hanging mechanism.
All the material was loaded up and taken to FKM welding laboratory to cut the
majority of the material to length using a grinding machine as shown in the figures below. In
this project we used 50mm x 25mm rectangular tube for the crane frame.We requested two
rectangular tubes that comes in 6 metre length, therefore we will have to cut into shorter
length according to our final design. The first 6 metre rectangular tube is used for the top
beam and side support beam. They were cut into 1800mm for the top beam and two pieces of

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

2000mm for the side support beam. The second 6 metre rectangular tube is used for the base
and base supports. They were cut into two pieces of 1000mm for base and four pieces of
765mm for base support. These material were planned and used properly to avoid
unnecessary scrap materials.
The cutting process of rectangular tube into the appropriate dimension using cut-off
saw. Precaution has to be taken when using cut-off saw especially when cutting long
material. The material must be properly support on both ends so that the material can lay flat
on the platform during cutting to ensure steady cutting process. It is also very important to
remember to adjust the spark shield so that the sparks is directed to the floor to prevent
injury.Drilling process during fabrication of the crane. 3 types of hole were drilled which are
M8, M10 and M12. M8 holes were drilled on the lower pulley system so that the hook can be
attached to it while M10 hole were drilled on 2 different side of the crane which are on the
base plate to attach the wheels and on the top and side beam to attach the plate gusset for
further support.
After all the parts have been cut to the required dimensions and drilled, then the
process of joining all parts was carried out by using shielded metal arc welding (SMAW). For
our project, welding has to be carried out carefully and in low ampere which is 70A to
prevent penetration because we are using hollow steel. The welding process of top beam.The
personal protective equipment (PPE) used throughout the project. Working gloves were used
to carry material such as steel to prevent injury from cut and welding glove is compulsory
when using shielded metal arc welding (SMAW) to prevent the sparks to get in contact with
the skin that will cause burn and the welding goggle is used to protect the eyes from the
bright arc. Besides, safety shoe is also compulsory when we enter to mechanical lab in FKM
to avoid foot injury.
Material used for hanging mechanism that we purchased from the hardware store. 4
metres nylon rope, 8 pulleys, 2 U-bolts, a hook and several bolts were purchased. 2 sets of
pulley system each consist of 4 pulleys were made by joining them with bolt. After joining
the pulley system, the rope was installed to serve as fully functional hanging mechanism.
Illustrates the wheels that were used on the crane so that it is portable and easier to move
from one site to another site during a well construction project. The wheel size used was
100mm in diameter and are free moving. They were joint using bolt and nut at the base of the
crane instead of welding so that they can be removed when not needed. Painting material
used for finishing on the crane. Red paint was chosen to be used on the crane body because it
is bright so that people will be more aware of it while black paint were used on the pulley so
that there will be a colour contrast to create awareness. The purpose of painting is also to
prevent corrosion on the crane from moisture so that it will be more durable and long lasting.

Detailed views of the pulley system that consist of 4 pulleys.They were all joint by
using a M8 and M6 bolt on the top and bottom respectively. After that, they were all painted
in black colour. Figure 7 shows the complete and fully functional crane painted in red colour.
The hanging mechanism was installed and the rope was attached to the pulley. The wheels
were also attached to the base of the crane using bolt and nut. The crane is then tested by
lifting several different weight objects.

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Figure 7: Final product of gantry crane.

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

FLOW CHART

Start

Discuss and choose topic

Sent proposal

Proposal
accepted?

Sketching and modelling

Analysis

Fabrication
Materials

Assembly

Test the product

Product meets
the objective?

Results and discussion

Presentation to supervisor

Presentation and project submit End

Figure 8: Flow chart

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

RESULT AND DISCUSSIONS

Concrete well
; ;

Available material
Option 1:
Option 2:

Option 1 Option 2
Area

Moment of
Inertia

Mass

Bending
stress

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Compression
stress ⁄ ⁄

Pulley Mechanism Calculation

Expected Load = 140 kg To Hoist

θ = 45 ̊

F =? F =?

140 Kg

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

SIMULATION
Later finite element analysis was perform using Siemens NX 9.0 with 2D meshing of 5mm
element size. In computational solutions of partial differential equations, meshing is a
discrete representation of the geometry that is involved in the problem. Essentially, it
partitions space into elements (or cells or zones) over which the equations can be
approximated. Zone boundaries can be free to create computationally best shaped zones, or
they can be fixed to represent internal or external boundaries within a model [14].In addition,
meshes also find extensive use in the analysis of geographical and cartographic data. All the
welding joint were stitch together to form solid joint exept for base plate which bonded by
surface gluing. Bolt and nut joint was simulated using rigid body element (RBE2& RBE3).
Load was link using RBE2 to form a uniform distributed load as shackle weldement, sames
goes with constraint. The simulation was then solve using NASTRAN SOL 101 & SOL 103.
The finite elementsconsist of 71473 Quad and 368 Triangle with 72487 nodes. Quadrilateral
element was majorly used over triangular element due to its advantages [15].

Figure 9: 2D Meshing of Well Hoist

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Load

Constraint

Figure 10:Rigid Body Element (RBE2) for load and constraint.

Static Analysis (NASTRAN SOL 101)

To ensure safety and operation, the deflection of their main beams under load should be
analyzed[16].A force of 1,373.4N was applied at the end of rigid body link which equalvelent
to a concrete well of 140kg with radius of 1.5m and 1m in height. The result show only 4.176
mm of deflection on the beam even though the mass of load was massive and the beam is
only 2 mm thick. Von mises stress is based on distortion energy theory which is more precise
[17] .

Figure 11: Deformation analysis

Then stress concentration was analysis, the result show highest stress value of 130.05 MPa at
the center of the beam which is only 14.8% less than caculated stress value. The zoom view
show how the effect of RBE2 act as weldment of shackle. The hoist also shows a factor of
safety of 3.46.

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Figure 12:Stress concentration analysis (Von Misses stress)

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Dynamic Analysis (NASTRAN SOL 103)

Stress on the structure leads to unwanted vibrations that lead to structural damages and
thereby reduced life span[18].Dynamic analysis is perform to show natural frequnecy or
mode which can be define as frequency at which convertion of kinectic to potential energy
and vise versa tend to occur. This modal analysis is also an effective way to determine the
natural frequency.Besides, natural frequency is also affected by the pay load mass and
pendulum length[19]. Natural frequency can represent stiffness behaviour [20] on a complex
structure in undefine load by comparing it natural frequency. As the frequency is higher the
structure is consider stiffer (not tend to deformedto) at respective mode shape. This can be
relate since natural frequency is the square of mass over stiffness.

Figure 13: Mode shape 11.048 Hz and 15.717 Hz.

Figure 14 :Mode shape 25.659 Hz and 40.979 Hz.

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Figure 15 : Mode shape 40.121 Hz and 52.794 Hz.

Figure 16 : Mode shape 99.823 Hz and 113.573 Hz.

From the dynamic analysis, it can be seen that the structure has least stiffness when being
bend foward or backward.

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

CONCLUSIONS

The main objective which is design and development of hanging mechanism during
concrete well construction is achieved and the hoist is fully functional. It can hoist a
common concrete well with weight of 140kg safely at 3.46 factor of safety. The structure is
expected to be able to hoist a weight up to 200kg in real situation due to strcuture
imperfection.When using 4 pulleys on the second pulley system which is near to the load,
there is an uneven force distribution and cause tilting of pulley to one side and this is due to
the presence of friction in the pulley mechanism. As for the pulley system, the calculation
shows that to hoist a 140kg concrete well material, each person will only have to exert a force
of 161.86N which is equilvalent to 16.5kg.

RECOMMENDATIONS

In future, this project can be improved by reducing the overall height to reduce its
weight for better transportation and for safety purpose to prevent people going underneath.
Besides, spray paint can be used instead of brush paint because it requires less drying time
and provides a better surface finish. Last but not least, the pulley mechanism can be improved
by using ball bearing and flexible so that friction can be reduced significantly.

ACKNOWLEDGEMENTS

We would like to thank to all lecturer of Mechanical system design especially our
supervisor Dr. Mohd Hafizi Zohari because helps us to gives some ideas and guide on our
project and broadening experiences. We also would like to thank to all laboratory instructor
for allowing our group to use some of toolsto build and finish our project. The authors would
like to be obliged to Universiti Malaysia Pahang for providing laboratory facilities and
financial assistance

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