STS Crane Modernization
Structural Innovation and FEM Precision in Port Operations
Project
Description
STS (Ship-To-Shore) Crane Modernization is a highly technical process aimed at upgrading and optimizing these critical structures for port operations. The project’s primary focus is to expand the operational capabilities of the cranes, particularly to handle post-Panamax and ultra-large vessels, which require increased height and reach. This modernization involves a combination of high-precision structural engineering and innovative technologies, including Finite Element Analysis (FEA), global stability and local buckling calculations, as well as simulations for both dynamic and static loads.
CADE has led numerous projects of this kind, demonstrating a consistent commitment to technical excellence and innovation. CADE’s experience spans all phases of the process—from initial structural evaluations via visual inspections and non-destructive testing to the 3D modeling and design of required modifications. Implemented solutions include extending the main structure, reinforcing beams and columns, and optimizing hoisting systems.
These projects incorporate advanced technologies such as hydraulic jacking for precise elevation and the installation of permanent reinforcements to ensure long-term stability and performance. Thanks to its experience and innovative approach, CADE has transformed port operations by enabling modernized cranes to significantly increase operational capacity while improving efficiency, safety, and reliability in a highly competitive environment.
Extra capacity for large vessel container handling
Time required for complete structure elevation
Full structural simulation with FEA technology
Reduced maintenance and port investment costs
Our
Technical Capabilities
Finite Element Analysis (FEA)
Finite element models are used to simulate structural behavior under various load conditions, evaluating stress distribution and deformation patterns.
Global Stability and Local Buckling Calculations
Axial forces and compressive stresses are calculated to ensure the structure remains stable and resistant to buckling failures.
Reinforcement of Portal Beams and Columns
Reinforcement beams and additional stiffness are added to columns using welded material and reinforced flanges.
Hoisting System Optimization
Cable drums are upgraded and new pulley systems are installed to accommodate the increased height, minimizing wear and improving operational efficiency.
Technical Planning
Phase-Based Execution
At CADE, we follow a structured technical planning approach for STS crane modernization, addressing each phase of the process in an integrated and efficient manner. From the initial assessment with detailed inspections and analyses to advanced 3D modeling and controlled execution with precision techniques like hydraulic jacking, we ensure a robust and reliable outcome.
Our method ensures modernization that improves crane operation, extends service life, and enhances performance to meet the highest international standards.
Structural Evaluation and Regulatory Compliance
Visual Inspection and Non-Destructive Testing (NDT):
Detailed inspections and tests such as ultrasound and X-rays are conducted on critical welds prior to intervention.Original Load Analysis:
A complete structural analysis is performed to identify potential failure points under both static and dynamic loading.
Modeling and Extension Design
Parametric 3D Modeling:
A comprehensive 3D model is developed to include all planned modifications, simulating maximum loads across all operational scenarios.Beam and Hoist Cable Reinforcements:
Traction loads on cables are calculated, and upper beam reinforcements are designed to withstand the new operational height.
Execution and Assembly
Structure Lifting via Hydraulic Jacking:
A hydraulic jacking system is used for controlled lifting of the crane. Weight distribution is continuously monitored, and temporary reinforcements are installed to prevent deformations.Installation of Permanent Reinforcements:
Additional beams are welded to columns, flanges are added for enhanced stiffness, and anchorage bases are adjusted to handle increased vertical loads.
Technical
Challenges
The height extension of STS cranes involves next-generation technical advances to optimize performance and meet modern demands. A key innovation is the use of high-precision jacking systems, enabling full structural elevation in as little as 24 hours with real-time load monitoring sensors. This ensures structural stability, preventing torsion or hazardous displacement.
Another critical enhancement is the boom extension to accommodate larger vessels. This requires recalibrating forestay angles and redesigning components such as the trolley to ensure that the hoisting system can support the new loads without compromising mechanical durability. These solutions showcase an advanced technical approach to meeting today’s port industry challenges.
