A mast crane – often also referred to as a pillar jib crane, column-mounted jib crane, or jib crane – is a stationary industrial crane with a vertical mast and a slewing jib. In deconstruction, strip-out, quarrying, and workshops it is used for safely lifting, positioning, and securing components, tools, and power units. Especially in combination with Darda GmbH’s hydraulic separation and splitting techniques, such as concrete demolition shears or rock and concrete splitters, a mast crane supports precise workflows and reduces risks during the controlled removal of components.
Definition: What is meant by mast crane
A mast crane is a locally fixed-mounted crane with a load-bearing column (mast) on which a slewing jib with trolley and hoisting unit (e.g., electric chain hoist) is installed. It allows lifting and horizontal slewing of loads within a defined radius. Typical slew ranges are 180° to 360°, and load capacities – depending on design and foundation – range from low to multi-ton. Mast cranes are used in halls, on assembly areas, and on construction sites to move loads safely, secure them, or hold them in assembly position.
Design and operating principle of a mast crane
The mast crane consists of a load-bearing column, a jib with trolley, a hoisting unit, and the anchorage to the ground. By slewing the jib and moving the trolley, loads can be moved radially and tangentially – ideal for tasks where components must be held or finely positioned.
Slew range and jib
The jib defines the working radius. Depending on the jib bearing and mast connection, slew ranges of 270° to 360° are common. The jib length influences the usable capacity: as the jib length increases, the moment on the mast increases, which can reduce the maximum permissible load.
Trolley and hoisting unit
A trolley runs on the jib and carries the hoisting unit. Electric chain hoists are common, wire rope hoists less so. For delicate components, stepless lifting and travel motions are advantageous to position loads gently – for example, when holding a concrete member that is being cut in a controlled manner with a concrete demolition shear.
Power supply and control
The hoist is supplied via festoon cable, energy chain, or conductor bar. Modern controls allow fine lift, soft start, and, if required, a lift limit. In dust- or spark-hazardous areas, special designs may be required; the relevant regulations and manufacturer instructions apply.
Anchorage and foundation
The mast is anchored via a base plate on a foundation or load-bearing floor slab. Alternatively, brackets on steel columns or walls are possible. Decisive factors are resisting the overturning moment and distributing the forces into the building structure.
Types and typical configurations
Depending on the application, mast cranes differ in geometry, capacity, and anchorage:
- Free-standing pillar jib crane: bolted to a foundation, 270°–360° slewing, variable radius.
- Guyed mast crane: jib guyed via tie-rod/strap, high stiffness with reduced dead weight.
- Low-profile design: for limited headroom to achieve maximum hook height.
- Mobile mast base with counterweights: for temporary use, e.g., in interior deconstruction with changing work locations (only after structural verification and in accordance with manufacturer specifications).
Technical parameters and selection criteria
The following parameters are central for sizing:
- Working load limit (WLL) in relation to the jib and slew range
- Jib length (working radius) and hook height (lower crane hook position)
- Slew range (e.g., 270° near walls, 360° free-standing)
- Foundation requirements (anchors, anchor bolts, concrete grade, edge distances)
- Environmental conditions (indoor, humidity, dust, wind for outdoor use)
Practical rule of thumb for load estimation: density of reinforced concrete approx. 2.4 t/m³. A slab 2.0 × 1.2 × 0.15 m has a volume of 0.36 m³ and weighs about 0.86 t. This allows reserves for slings and tools when a mast crane holds components during cutting.
Interaction with tools and methods from Darda GmbH
In controlled deconstruction, the mast crane complements Darda GmbH hydraulic tools effectively:
- Concrete demolition shears: A mast crane can hold components, pre-tension them, or secure them against uncontrolled tipping while the shear separates the element from reinforcement and connection points.
- Rock and concrete splitters as well as stone splitting cylinders: After drilling the holes and splitting, loosened blocks or concrete bodies can be transported away on the crane hook; at the same time, the mast crane can keep the component in position before the final split.
- Hydraulic Power Units: Chain hoists on the mast crane facilitate the safe repositioning of the power units, especially along constrained routes indoors.
- Combination shears, multi cutters, steel shears: The crane supports handling of cut material (e.g., steel beams, rebar bundles) and intermediate staging in defined zones.
- Tank cutters: When segmenting vessels, the mast crane can secure, lower, and place segments in an orderly fashion. Appropriate equipment concepts must be provided in potentially hazardous areas.
Use in concrete demolition and specialized deconstruction
In concrete demolition and special deconstruction, selective deconstruction is often performed top-down. A mast crane with sufficient hook height and suitable capacity holds components while concrete demolition shears sever connection reinforcement. Advantages:
- Controlled load management instead of demolition by drop energy
- Reduced vibrations in existing structures
- Targeted placement in drop or sorting areas
For massive elements, the combination of rock and concrete splitters and a mast crane can accelerate dismantling: the splitter reduces cross-sections, the mast crane takes the load and prevents unwanted cracks or edge breakouts.
Mast crane in strip-out and cutting
During strip-out, plant components, machine foundations, or floor slabs are removed in segments. A mast crane enables ergonomic handling of heavy equipment (e.g., hydraulic power packs) and safe repositioning of components after the cut with multi cutters or combination shears. Where headroom is limited, low-profile jib cranes are common, yet still providing sufficient hook height for the chain hoist’s lifting travel.
Role in rock excavation, tunneling, and natural stone extraction
On forecourts, in workshops, or at portal areas, mast cranes handle heavy components, drill carriages, splitting cylinders, and block material. After using rock and concrete splitters, loosened rock blocks can be rotated in a controlled manner and set down onto processing or transport equipment. In tunnel advance works, mast cranes support tool changes and servicing of power units in ancillary rooms.
Special applications and tight constraints
Where space is tight, floor load capacity is limited, or environments are sensitive (e.g., laboratory areas), mast cranes with a small footprint and limited slew range are an option. Mobile mast bases with counterweights may be considered; however, this requires careful structural analysis and suitable operating instructions.
Safe work procedures and slings
Safe crane work depends on appropriate slings and clear procedures:
- Determine the load: dimensions, material, reinforcement content, additional loads (e.g., residual attachments).
- Select slings: chain slings, web slings, shackles, spreader bars – sized for the required sling angles.
- Keep the load path clear: clear the slew range and set-down areas; define communication paths.
- Trial lift: lift the load slightly, check the center of gravity, correct the sling.
- Synchronize work: coordinate cutting or splitting operations with crane operation.
Important: Choose attachment points so that components do not jam when being cut. For concrete demolition shear operations, a second sling for tilting or rotating is often useful.
Planning, structural analysis, and installation
Anchoring the mast requires suitable load transfer. Foundation size, concrete grade, edge distances, and anchors/anchor bolts must match the maximum overturning and horizontal loads. In existing buildings, the load-bearing capacity of floor slabs, beams, and columns must be verified. For outdoor use, the wind load on freely suspended loads must be considered. Assembly follows manufacturer specifications; test certificates and approvals must be organized in accordance with applicable regulations.
Maintenance, inspection, and operation
Mast cranes and hoists are subject to regular inspections by qualified persons. Visual checks before use, lubrication and care of bearings, inspection of anchors, and checks of chains, hooks, and safeties are standard. Operating manuals and operating instructions are authoritative; they also define operating limits (e.g., maximum load, slew speed, use under special environmental conditions).
Sizing in deconstruction: practical guidance
For an initial estimate in combination with Darda GmbH tools:
- Wall segments: 3.0 × 0.5 × 0.20 m = 0.30 m³ → approx. 0.72 t; plus reserve for slings.
- Slab fields: 1.8 × 1.8 × 0.18 m = 0.58 m³ → approx. 1.39 t; if necessary, cross-section reduced by rock and concrete splitters prior to lifting.
- Steel beams after the cut: determine weight from cross-section and length; control tipping behavior with a spreader bar.
The selected capacity should include reserves for dynamic effects and incomplete load uptake. In case of uncertainty, refer to the documentation and pertinent regulations.
Work organization and ergonomics
A mast crane shortens paths and minimizes manual handling. Structured placement of hydraulic power packs within the crane radius, defined set-down areas for separated components, and short, clear communication chains between operators improve productivity and safety. Sensitive controls support precise positioning – an advantage when working with concrete demolition shears in sensitive environments.