Lifting frame FEA and structural certification.
Case study: structural FEA and engineering certification of a 40-tonne lifting frame used for the installation of pre-fabricated concrete panels on a NSW construction site — to AS 1418, AS 3990 and AS 4991.
Project overview
A construction contractor required structural FEA and certification of a custom 40-tonne lifting frame designed to install pre-fabricated concrete wall panels on a high-rise residential project in Sydney. The frame had to handle panels up to 14 m long and provide rotational adjustment during placement.
The challenge
The frame was an evolution of an existing design but with significantly larger panel masses. The original design had no FEA or third-party certification. WorkSafe NSW required full lifting equipment certification to AS 4991 before site use.
Our approach
- Full FEA of frame under static, dynamic and abnormal load cases per AS 4991
- Fatigue analysis based on expected lift cycles
- Connection bolt analysis and slip-critical joint design
- Welding examination plan to AS/NZS 1554.1
- Engineering certification documentation for WorkSafe NSW
Deliverables
- FEA report with stress contours and safety factors per AS 4991
- Structural calculations and load schedules
- Welding map with NDT requirements
- Operations and maintenance manual
- Engineering certification suitable for site registration
Outcome
The frame was certified and registered for site use within the contractor’s programme. Over 320 panels were installed with no incidents or load failures. The frame remains in service four years later, with quarterly NDT inspections passing without findings.