A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

A Design of Fabricated Concrete Foundation for Tower Crane

1

LIU Jin-long, 2 LI Chang-hua

Department of Civil Engineering of Hefei University, Hefei city Anhui Province
China 230601, E-mail:alnile@163.com
*2,Corresponding Author
Department of Civil Engineering of Hefei University, Hefei city Anhui
Province China 230601, E-mail: licho@hfuu.edu.cn

1, First Author

Abstract
A fabricated concrete foundation for tower crane has been proposed in this article, according to
lots of limitations of traditional in-situ concrete foundation. The fabricated concrete foundation
composed with 13 fabricated blocks and combined by steel strands, which bearing the vertical force,
horizontal force, twist moment and bending moment induced by tower crane, characterized with
combined, decomposed, transited and repeated use. Based on the finite element method, the
deformation of foundation block and ground has been further studied. It is worth to do more research
and extension on fabricated concrete foundation of tower crane.

Keywords: tower crane, fabricated, foundation, finite element method

1. Introduction
Tower crane is absolutely necessarily machine in industry and civil construction. Until 2010, there
are more than 500000 tower cranes used in large numbers of construction sites of world. As a
constructing country, China has the most projects in the world. There are more than 250000 tower
cranes, half of the total number of tower cranes, used in Chinese all kinds of engineering [1, 2].
During the using of tower crane, the foundation of tower crane acts an important role. However,
there is no code the guide the design of tower crane foundation. Usually, cast in-situ steel concrete has
been used to construct tower crane foundation, which has lots of limitations as following [3-5]:
(1) It need long time to dig foundation ditch, depositing concrete, concrete curing and removal
foundation after finish engineering. More than 15 days is needs to finish a cast in-situ steel concrete
foundation, which has some influence on the whole construction period of engineering.
(2) According to statistics, it is more than 20000 RMB needs to finish a cast in-situ steel concrete
foundation of tower crane. In China, there are more than 6.90 billion RMB cost in tower crane
foundation a year, which gradually increased in this years.
(3) There are lots of building rubbish generated by in-situ steel concrete foundation of tower crane,
which could no agree with the need of civilized construction and environmental protection.
(4) There are lots kinds of tower crane foundation, which could not be exchanged or circulated each
other, and could no be used repeatedly by fixing.
(5) If there are some equipments, such as septic tank, pipeline of gas, water or telecommunication,
should across the position of tower crane foundation after the main construction end, then the in-situ
steel concrete foundation of tower crane should be cleared after using, which is hard to disposing.
(6) It is need big bearing capacity of foundation, always bigger than 200kPa, to suit the in-situ steel
concrete foundation of tower crane. So foundation treatment should be done in soft soil foundation area,
which enhanced the cost of construction.
(7) Conservation-oriented society, circular economy and capital reduction are the aims and guides
of our engineering activities. But the typical steel concrete foundation of tower crane could not agree
with this criterion.
According to the limitation of steel concrete foundation of tower crane, some model of fabricated
concrete foundation for tower crane have been proposed by researchers [5-12]. But the new structural
foundation of tower crane has not been used widely, which need to be improved and promoted.
A new design of fabricated concrete foundation for tower crane will be proposed in this
article, which combined 13 blocks with unbonded prestressed level connection system, and
could bearing the horizontal force, torque and moment generated by tower crane effectively, and

International Journal of Advancements in Computing Technology(IJACT)

Volume5,Number6,March 2013
doi:10.4156/ijact.vol5.issue6.110

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

also could be combined, decomposed, transited and repeated use, which has been applied for
patent of China successfully [13].

2. A design of fabricated concrete foundation

In this article, the foundation of QTZ125 tower crane (attachment working type) is to be
studied. According to the description of tower crane, vertical load P1 820kN , horizontal load
at top surface of foundation P2 40kN and bending moment M 2380kN m would be applied
at foundation at working condition, vertical load P1 740kN , horizontal load at top surface of
foundation P2 65kN and bending moment M 3200kN m would be applied at foundation at
non working condition.

2.1. Estimation of basal area of foundation

The tower crane could rotate 360 at working, so every direction of foundation maybe the
dangerous and controlled surface. In order to adapt the character of tower crane, a circular section of
foundation for tower crane is proposed in this article. Cross type beams are used to combine and
strengthen different blocks. The height of cross type beam is 1.1 m, and the height of support is 1.5 m,
the bearing capacity of ground is f a 130kPa . A circular section with diameter of 7.0 m is estimated
for the foundation of tower crane. According to the code of foundation [14], the corresponding
calculation steps are showed as following:

(a) Working condition

N G M 820 3.5 2 1.1 25 2380 480 40 1.5

0
(1)

A
W
3.52
3.53
4
Where pmin is the minimal base pressure of foundation, N is vertical load of tower crane, G is gravity
of foundation, A is the basal area of foundation, M is the bending moment of tower crane, W is the
sectional resistance moment of foundation.
The pressure of foundation would be readjust and redistribute for pmin 0 could not valued in reality.
After readjustment, pmin 0 , and the maximal base pressure of foundation p max calculated as:
2920
M
1.55 m, a=3.5-1.55=1.95 m

e
N G 1878
2N G
2 1878
(2)

91.72kPa
pmax
3la
3 1.95 7
Where e is the eccentric distance of composite force, l is the length of foundation, a is the distance
between application point of composite force and fringe of foundation.
pmin

(b) Non working condition

N G M 740 3.5 2 1.1 25 3200 65 1.5

0
(3)

A
W
3.52
3.53
4
The pressure of foundation would be readjust and redistribute for pmin 0 could not valued in
reality. After readjustment, pmin 0 , and the maximal base pressure of foundation p max calculated as:
3298
M

1.83 m , a=3.5-1.83=1.67 m
e
N G 1798
2 N G
2 1798
(4)

102.5kPa
pmax
3la
3 1.67 7
pmin

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

According to the two conditions mentioned above, the maximal base pressure of
foundation pmax102.5kPa . pmax 1.2 f a 156kPa , so the circular section with diameter of 7.0
m could agree with the need of QTZ125 tower crane during estimation.

2.2. Design of fabricated concrete foundation

Considering all kinds of influence, the model of fabricated concrete foundation of tower crane has
been designed, which combined by block A, block B, block C and block D, as showed in figure 1~
figure 4. There are total 13413 blocks, which combination as a circle with diameter of 7.0 m. In
order to strengthen the validity and integrity of combination, convex and concave parts have been set
on blocks. The 13 blocks could be combined by steel strands through the holes prepared in cross type
beams. The character of each block is showed in table 1.
Convex and concave parts

Foundation bolt
Convex and concave parts

Foundation bolt

Block D Block C Block B Block A

Concrete cushion with thickness of 15cm
Symmetry axis

(a) Floor plan

(b) A1A1cross section
Figure 1. Layout of fabricated concrete foundation of tower crane
Block D

Block C

Block B

Block A

(a) Before assembly

(b) After assembly
Figure 2. Quarter renderings of fabricated concrete foundation of tower crane

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

Figure 3. Overall renderings of fabricated concrete foundation of tower crane

Table 1. Character of each block of fabricated concrete foundation of tower crane
Number
Maximal
Maximal
Maximal
Area of
Volume
Weight
of block
length /m
width /m
height /m
base /m2
/m3
/kN
A
B
C
D

1.2
2.8
4.2
4.2

1.2
0.9
0.9
0.9

1.2
1.7
1.2
1.2

1.4
1.71
3.27
3.06

1.488
1.80
1.30
1.26

37.2
45.0
32.5
31.5

2.3. Checking basal area of foundation

According to the code of tower crane[15], the basal area of foundation should meet the control
equations showed as following:
M Fh h b
e

(5)
Fv Fg
3

pB

2( Fv Fg )

(6)
pB
3bl
Where FV is the vertical load of foundation, Fh is the horizontal load of foundation, Fg is the gravity
of foundation, p B is the compressive stress under foundation, [ p B ] is the allowable compressive stress
under foundation, b is the width of foundation. The basal area of foundation could be checked as
following:
(a) Working condition:
b 6. 6
2380 480 40 1.5
e
2.26m
2.20m , which unsatisfied equation (5).
820 473
3
3
(b) Non working condition:
b 6. 6
3200 65 1.5
e
2.72m
2.20m , which unsatisfied equation (5).
740 473
3
3
Additional weight is needs to improve the stress condition foundation in order to satisfy
equation (5). According to the specification of tower crane, 520.0 kN additional weight should be layaside at top of foundation uniformly. It could be divided as 24 rectangular solids, each weighted 22.0
kN, total weighted as 2422=528.0 kN, uniformly arranged in the four sector of top foundation. Then,
the total weight of foundation including additional weight is G473+5281001 kN.
In a certain degree, the non working condition is the control condition. Now the basal area of
foundation could be rechecked for non work condition as following:
b 6.6
3200 65 1.5
e
1.89 m
2.20m which satisfied equation (5).
3
3
740 1001
2(740 1001)
124.7 kPa p B =130kPa, which satisfied equation (6).
pB
3 6.6 (3.3 1.89)

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

Therefore, the foundation with circular section with diameter of 7.0 m proposed in this article
could agree with the bearing capacity of 130kPa of ground. Considering the convenience of
construction and transport, the 520.0 kN additional weight could be divided as 24 pieces of
2.0m1.0m0.45m concrete blocks. Some other existing equal ponderous object could also be used as
additional weight certainly.
The comparative analysis between fabricated concrete and in-situ concrete foundation of tower
crane is showed in table 2. It can be found the weight of fabricated concrete foundation (additional
weight excepted) is less than that of in-situ concrete foundation.

Table.2 Comparative analysis between fabricated concrete and in-situ concrete foundation
5m5m1.1m In-situ
6m6m1.1m In-situ
The design proposed in this
Type
concrete foundation
article(additional weight excepted)
concrete foundation
weight/kN

473.0

690.0

990.0

In addition, when the bearing capacity of ground is bigger than 130 kPa, the additional weight
could be reduced. The relationship between ground bearing capacity and additional weight for
foundation is showed in table 2. In order to enhance the stability of foundation of tower crane, it is
strongly suggested that additional weight should no be less than 150.0 kN. The aerial view of
fabricated concrete foundation of tower crane with additional weight proposed in this article is showed
in figure 4.

Table. 3 Relationship between ground bearing capacity and additional weight of foundation
fa / kPa
130
150
170
190
210
Additional weight / kN
528.0
281.0
181.0
122.0
81.0
Note: it is strongly suggested that additional weight should no be less than 150.0 kN

230
52.0

Figure 4. Aerial view of fabricated concrete foundation of tower crane with additional weight

2.4. Design of steel strand

The key problem of this design is that how the 13 blocks be assembled as an integral foundation
to bear the vertical load, horizontal load and bending moment generated by tower crane. In this design,
13 blocks could be combined by steel strands through the holes prepared in cross type beams. Now, the
number and strength of steel strands are to be designed and calculated.
The combination of forces directly applied at supporting blocks B, which should be effectively
delivered to blocks A, blocks C and blocks D through frictional force between each block. Therefore,
the maximal and dangerous frictional force between each block should be calculated firstly. The
distribution of base pressure at the most dangerous situation of fabricated concrete foundation of tower
crane is showed in figure 5.

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

Foundation bolt

Block A Block B Block C Block D

Figure 5. Distribution of base pressure at dangerous situation of fabricated concrete foundation

According to figure 5, the maximal and dangerous frictional force between each blocks could be
calculated, which is about 414.6kN. Therefore, the axis force of steel strands should larger enough to
generate frictional force414.6kN to combine the 13 blocks into integrality effectively. The frictional
force controlled by coefficient of friction and normal force, as showed following:
N' Q
(7)
Where: is the coefficient of friction between each block, N ' is the normal force between each block,
Q is the frictional force between each block. In fact, there are lots of factors influenced the value of
coefficient of friction between each block, such as degree of roughness of contact surface, degree of
wetting and drying of contact surface, value of normal force, shape and area of contact surface, and so
on. In a certain degree, the value of coefficient of friction fluctuated in the interval of 0.2~0.7. The
relationship between coefficient of friction and axis force of steel strands is showed in table 4.

Table. 4 Relationship between coefficient of friction and axis force of steel wires
Coefficient of friction

Axis force of steel strands / kN

0.2
2075

0.3
1384

0.4
1038

0.5
830

0.6
692

0.7
593

Tests should carry out to define the exact value of coefficient of friction between each block,
which needs much manpower, resources and cost. In fact, it is safety to assign coefficient of friction
with a low value. According to lots of references, coefficient of friction 0.3 is used in this article, so
axis force of steel strands of 1384 kN needed from table 4. Now the number of steel strands is to be
calculated further.
Unbonded prestressed steel strands are to be used, with the character of 1 7 standard form,
nominal diameter d 15.2mm , nominal cross section area Ap 139mm 2 and normal value of
strength f ptk 1860 N/mm 2 .The tension control stress of steel strands con could be valued

as con 0.65 f ptk conservatively, that is: con 0.65 f ptk 0.65 1860 1209 N/mm 2 .
Loss of prestress includes 3 parts, as described as following:
(1) l1 , loss of prestress induced by deformation of anchor device and steel strands
5
a
l1 E
1.95 10 5 147.7 N/mm 2
6600
l
Where: a is the value of deformation of anchor device and steel strands, according to the
code a 5 mm . l is he length of steel strands, l 6.6 m 6600 mm . E is the elastic ratio of steel
strands, E 1.95 10 5 N/mm 2 .
(2) l 2 , loss of prestress induced by friction neglected: l 2 0

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

(3) l 4,5 , loss of prestress induced by creep of concrete and looseness of steel strands,

l 4,5 230 N/mm 2 .

So, the total loss of prestress is l l1 l 2 l 4,5 377.7 N/mm 2 .Then the effective prestress

pe between blocks is pe con l 1209 377.7 831.8N/mm 2 .The axis force of each steel
strand N1 is: N1 Ap1 pe 115550.7 N 115.56kN .
The total number of steel strands n could be confined as:
N
1384
n

11.96
N1 115.56
In order to enhance the stability of foundation and eliminate the influence of indeterminacy, the
total number of steel strands n 15 is to be used conservatively in this design.
There are 3 circular preformed holes in the cross beams of foundation, as showed in figure 2.
Seamless steel pipes with inner diameter 65 mm and wall thickness 3mm have been fixed in the
concrete to mold the performed holes. There is 1 preformed hole on the top of cross beams, and
the remained 2 preformed holes on the bottom of cross beams horizontally, as showed in figure
3. The 13 bocks could be combined with steel strands through the preformed holes. 5 steel
strands as a cluster is allocated at each preformed hole. It could be consult the corresponding
codes or books to know the technique and steps of how to combine13 fabricated bocks into a
whole with steel strands.

3. Simulation working capacity of fabricated concrete foundation

In order to discuss the working capacity of fabricated concrete foundation further, finite element
method (FEM) would be used to study the character of fabricated concrete foundation proposed in this
article[16, 17]. Considering the symmetrical characteristic of foundation, the model could be simplified
as plane strain problem. The model of FEM is showed in figure 6.

Figure 6. Model of FEM

In order to catch the key influences and simplify the calculation of FEM, some assumptions would
be used in this simulation as described as following:
(1) The load induced by tower crane during working or non working condition are multivariate and
nondeterministic state at anytime, sometimes including dynamic load effect, so it is difficult to
simulate the real-time load of tower crane. So the load of tower crane is treated as constant value in
FEM, ignoring the effect of loading and unloading.
(2) There are some observable dynamic loads induced by tower crane during working or non
working condition, such as wind load and earthquake load. The dynamic loads could be transferred as
static load by pseudo static method.
(3) The stress and stain of ground under fabricated concrete foundation is not the key point of this
simulation, so the soil of ground could be assigned with high strength and big parameters. The soil of
ground could be simulated with Mohr-Coulomb failure criterion.
(4) There is no glide or slipping between bottom of foundation and ground, and the bottom of
foundation is entirely contact with ground.

3.1. Stress of foundation induced by steel strand

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

Figure 7. Distribution of horizontal stress

in fabricated concrete foundation

Figure 8. Distribution of stress vector

in fabricated concrete foundation

Steel strands at each hole would be tensioned arrive at the assigned axis force and fixed by
equipment. The distribution of horizontal stress in fabricated concrete foundation after combined by
steel strand is showed in figure 7. Due to there are 2 holes side by side allocated at the bottom of cross
beam, the force of bottom holes is twice of that at upside hole in FEM model. So it can be found the
horizontal stress around bottom holes is bigger than that of upside hole. The distribution of stress
vector in fabricated concrete foundation after combined by steel strand is showed in figure 8. It also
can be found the stress vector around bottom holes is bigger than that of upside hole. There is obvious
stress concentration around both ends of steel strands. In order to avoid local destroyed by stress
concentration, some measures should be used to disperse the stress around the ends of steel strands,
such as steel plate could buried at the neighbor of hole ends.

3.2. Deformation of foundation induced at working condition

The distribution of vertical settlement in fabricated concrete foundation at working condition is
showed in figure 9. It can be found the deformation around one supporting is obviously bigger than that
of another supporting by bending moment of tower crane, which could also be proved in the
distribution of incremental vertical settlement in fabricated concrete foundation, as showed in figure 10.
The total stress of fabricated concrete foundation at working condition is showed in figure 11, and
the incremental total stress of fabricated concrete foundation is showed in figure 12. It also can be
found that the stress around one supporting is obviously bigger than that of another supporting by
bending moment of tower crane at working condition.

Figure 9. Distribution of vertical settlement

in fabricated concrete foundation

Figure 11. Total stress of fabricated concrete

Figure 10. Distribution of incremental vertical

settlement in fabricated concrete foundation

Figure 12. Incremental total stress of fabricated

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

foundation at working condition

concrete foundation at working condition

Therefore, the bending moment of tower crane is the key factor induced unbalance stress or strain
in fabricated concrete foundation, which also made the foundation in dangerous state. It is necessary to
reduce bending moment of tower crane at work condition or non working condition. The integrity of 13
fabricated blocks depends on the friction between each block and the effect of steel strand. The force at
supporting block should be delivered effectively to other blocks, and the whole fabricated foundation
should remain a big safety stock to deal with all kinds of dangerous conditions.

3.3. Deformation of ground under fabricated concrete foundation

There are stress and strain in ground induced by fabricated concrete foundation with tower crane.
It is safety if the ground with big bearing capacity and high strength. In a certain degree, settlement and
differential settlement is the key controlling parameters of ground during working of tower crane. So
the fabricated concrete foundation should be set at ground with big bearing capacity, no less than
130kPa generally.
The vertical settlement of ground during fabricated concrete foundation working is showed in
figure 13. There is obvious settlement and differential settlement in ground induced by tower crane.
The value of settlement and differential decreased with depth of ground increased.
The lateral displacement of ground during fabricated concrete foundation working is showed in
figure 14. It can be found the lateral displacement of ground probably symmetrically distributed around
axis of fabricated concrete foundation, which similar with that of embankment.

Figure 13. Vertical settlement of ground

under fabricated concrete foundation

Figure 14. Lateral displacement of ground under

fabricated concrete foundation

The vertical stress of ground during fabricated concrete foundation working is showed in figure
15. There is obvious stress difference in ground induced by tower crane. The value of stress difference
decreased with depth of ground increased.

Figure 15. Vertical stress of ground during fabricated concrete foundation working
Due to the uneven force distribute on different supporting blocks B, stress difference and stain
difference induced in fabricated concrete foundation, and stress difference and stain difference induced
in ground under foundation further. In order to eliminate the influence of stress difference in
foundation or ground, the integrity of 13 blocks combined with steel strands should be guaranteed and
strengthened effectively, and the bearing capacity of foundation should be large enough. So the

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A Design of Fabricated Concrete Foundation for Tower Crane

LIU Jin-long, LI Chang-hua

fabricated concrete foundation proposed in this article could be used in soft soil ground only when it
has been reinforced with foundation treatment method sufficiently.
In a word, enormous economic benefits can get by fabricated concrete foundation, which well
meeting with the aim of conservation-oriented society, development of circular economy and
energy saving. It is worth to do more research and extension on fabricated concrete foundation
of tower crane.

4. Conclusions
(1) Tower crane is absolutely necessarily machine in industry and civil construction. In-situ steel
concrete has been used to construct tower crane foundation usually, which have lots of limitations.
(2) A fabricated concrete foundation for tower crane has been proposed in this article, according to
lots of limitations of traditional in-situ concrete foundation. The fabricated concrete foundation
composed with 13 fabricated blocks and combined by steel strands, which bearing the vertical force,
horizontal force, twist moment and bending moment induced by tower crane, characterized with
combined, decomposed, transited and repeated use.
(3) The bending moment of tower crane is the key factor induced unbalance stress or strain in
fabricated concrete foundation, which also made the foundation in dangerous state. It is necessary to
reduce bending moment of tower crane at work condition or non working condition.
(4) The force at supporting block should be delivered effectively to other blocks. The integrity of
13 fabricated blocks depends on the friction between each block and the effect of steel strand. That is,
the axis force of steel strands should larger enough to generate frictional force to combine the 13
blocks into integrality effectively.

5. Acknowledgment
This work was financially supported by Anhui Provincial Natural Science Foundation (No.
1208085QE89).

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