Mast crane

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. Used correctly, it shortens workflows, reduces manual handling, and contributes to repeatable, low-risk execution of lifting and holding tasks.

Definition: What is meant by a mast crane?

A mast crane is a locally fixed, column-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. Compared with overhead traveling systems, a mast crane covers a sector-shaped working area close to the work face and can be installed with a compact footprint.

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. Depending on the model, slewing may be manual or motorized, with mechanical end-stops or limiters to restrict the working sector where required.

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. Overbraced jibs with tie-rods offer low dead weight with high stiffness, while low-profile jibs maximize hook height where headroom is restricted.

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. Inverter-controlled drives support precise, low-sway handling; overload protection and upper-lower limit switches are essential safety elements.

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. Handheld pendants and radio remote controls are common, with emergency stop and key switch concepts to prevent unintended operation. 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. Typical solutions include cast-in anchor cages or post-installed anchors; base-plate leveling by grout and shims ensures proper load transfer. Concrete cone breakout, edge distances, and punching resistance must be verified in design.

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).
• Motorized slewing and trolley travel: for higher throughput, reduced operator effort, and repeatable positioning.
• Corrosion-protected or spark-reduced execution: for humid, abrasive, or sensitive environments.

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)
• Duty cycle and utilization class (frequency of lifts, starts per hour)
• Allowable deflection at jib tip and required positioning accuracy
• Interfaces for attachments and rigging accessories (lifting points, spreaders, quick connectors)

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. Where multiple workstations are served, overlap of working radii and collision avoidance must be coordinated in the layout.

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.

Coordinated rigging plans and pre-lift briefings align tool operation and crane motion, minimizing dwell times and interfaces.

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
• Lower dust resuspension and reduced noise compared with impact-based removal
• Clean separation lines that limit rework on adjacent finishes

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. Edge protection, proper sequencing, and cutting from the free edge toward the fixed connection support stable load paths throughout the operation.

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. Clear sequencing, component labeling, and defined interim storage areas improve logistics; changes in the center of gravity during release must be anticipated in the rigging plan.

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. Abrasive dust and moisture require sealed controls, protected power feeds, and routine cleaning to keep brakes and bearings reliable.

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.

• Mechanical slew limiters and travel stops can confine movements to safe sectors.
• Low-vibration installation methods and temporary mats help protect sensitive floors.

Safe work procedures and slings

Safe crane work depends on appropriate slings and clear procedures:

1. Determine the load: dimensions, material, reinforcement content, additional loads (e.g., residual attachments).
2. Select slings: chain slings, web slings, shackles, spreader bars – sized for the required sling angles.
3. Keep the load path clear: clear the slew range and set-down areas; define communication paths.
4. Trial lift: lift the load slightly, check the center of gravity, correct the sling.
5. Synchronize work: coordinate cutting or splitting operations with crane operation.
6. Inspect all slings and lifting points for wear, nicks, correct identification, and compatibility.
7. Establish exclusion zones and, where necessary, use tag lines to control rotation and sway.

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.

Note: Protect slings at sharp edges, avoid side pulling, and never lift over occupied areas.

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.

• Typical deliverables: anchorage plan with bolt layout and leveling concept
• Structural verification of base slab or foundation, including concrete breakout and pull-out checks
• Method statement for installation, commissioning, and functional testing
• Records of proof load tests, limit switch checks, and operator instructions

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). Defined inspection intervals, a maintained logbook, chain elongation checks with gauges, and timely replacement of deformed hooks or damaged latches increase availability and safety. Functional tests of end stops, brakes, and emergency stop circuits should be documented.

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.
• Stair flight: 1.5 × 1.2 × 0.18 m = 0.32 m³ → approx. 0.77 t; reinforcement density may increase the total mass.

The selected capacity should include reserves for dynamic effects and incomplete load uptake. In case of uncertainty, refer to the documentation and pertinent regulations. Sling angles strongly influence line loads; using a spreader can maintain higher angles and reduce compressive forces on the component.

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.

• Color-coded zones and floor markings reduce misplacement and rehandling.
• Pre-assembled rigging on designated hangers speeds up changeovers.
• Consistent hand signals or radio protocol prevent misunderstandings under noise and dust.