Presentation to the
Crane Safety Symposium 2017
Advances in Crane Safety Technology
Smart Crane
Solution for Dr Meghdad Attarzadeh
NTU
Safe Hoisting Meghdad@ntu.edu.sg
23 October 2017
Outline
1. Problem Statement & Current Challenges
2. The Developed System
3. Project Innovations
4. Pilot Project
5. Productivity Improvement
6. Future Collaboration - Smart Hoisting for Heavy Precast
Problem statement & Current Challenges
Current Practice: experiencing a major shift from the traditional methods
of intensive manual labour towards the utilization of automation.
The Processes and Operations
are Manually, Human-based, 2D
Problems
CAD and paper-based, Human Un-safe environment for
Problems
judgement (errors, inefficiencies
and delays) workers at construction and
installation levels (Safety Risks)
Critical paths of construction
process are affected by several
unavoidable/ unmitigated Lack of awareness of crane
constraints (leads to delays) operator lead to injury, fatality
Manual operations impose
constraints on the optimum Works on site are not designed
numbers of hoisting and to be fail-safe
installation operations, affecting
the cycle time
Objective
To enhance the Workplace Safety and Health (WSH) for construction
site logistics management, Hoisting and Installation processes for the
heavy lifting of Precast Elements.
Manual process prone to human errors
Human errors can be very costly
“Blind Spots” in tower crane hoisting
Low Productivity for Hoisting Process
Miscommunication can be very dangerous
No reference to BIM design platform
The Developed System
A safe, reliable, intelligent and semi-automated logistics and crane navigation system:
1) Integrated Digital Delivery (IDD);
2) Network of internet of things (IoT);
3) Signal parameters (Digital IDs) are collected through the various smart sensors
(RFID systems-Material Tracking);
4) Wireless smart sensors network along with smart camera technologies help for
tracking and monitoring of operations;
5) Computerised simulation system for sequencing activities to avoid activities clashes,
can be used for JIT delivery;
6) Able to auto-detect and semi auto-position the precast element closer to its
coordinate with micro-adjustment to be done by operator (Smart
Hoisting/Installation);
7) Information are displayed in the LCD Touch screen to guide the crane operator.
Presentation on Project:
“Implementation of a Smart and Semi-Automated Precast
Elements Logistics Management and Installation System”
Objective Enhancing the Productivity, Efficiency and Safety of the Precast Elements Logistics
Management, Hoisting and Installation process of housing projects through BIM based semi-
automated System integrated with Positioning and sensor technologies.
Deliverables Funding Agency: BCA (PIP Scheme)
Development of applications and add-ons to support R&D, Co-Applicant: NTU –CoE for BIM
functions in the proposed process for the smart crane Industry Partner, Main Contractor, Applicant: Kimly
system, such as scheduling, coordination, sequencing, Support by: SLA for SiReNT
on-site inventory checks and assembly. Technology Partners: Trimble SEA (BIM), Geoscience
Development of good practice guidelines for the
Consulting (GPS) and Intrasys (RFID) Vendors
proposed system.
Host of site visit(s) for industry when notified by BCA. Project development period: Dec. 2015-Oct 2017
Share experiences gained from the PIP with the Pilot Project: Executive Condominium Housing Development
industry. Comprising 11 Blocks Of 12 Storey Residential Buildings (525 Units)
Submission of a case study report on the use and located at Yishun Street 51 (Y51EC). We have focused on Blocks 7&8
for implementation of the proposed system.
operation of system.
Main Characteristics and Benefits of The Developed
System
1) Provide a holistic precast components logistics management, inventory checking and tracking, hoisting and installation
system.
2) Generate digital identification code for precast components, able to integrate the Logistic Management and SMART
crane system with BIM.
3) The system updates database and Building Information Model automatically.
4) The system supports worksite for JIT delivery and stock/inventory control. It provides information of the progress at
construction site which helps to meet JIT delivery (BIM-based construction site JIT inventory checking and tracking system)
5) SMART crane semi-auto system pre-determine the actual installation coordinates of the component based on the Building
Information Model.
6) SMART crane semi-auto system helps to semi-automatically detect, hoist and locate the precast component at the final
setting location.
7) Crane Operator still control the crane, do micro-adjustment to lower the component into final position.
Components structure of the Developed
System Information flow for the developed system
RFID
System
Data collection during the delivery to site, storage, erection and installation
Functionality of the Developed System
SMART Crane System
BIM-based semi-automated System integrated with Positioning and sensor technologies
Includes two parts:
1. Semi Auto-detection, track & collection of precast
elements.
2. Semi Auto-position and tracking to assist the crane
operator precast elements to identified locations.
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
System structure and functionality of the Developed BIM-based semi-automated System
Integrated with Positioning and sensor technologies
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
BIM to Database, Precast BIM system integrated with database,
real time position and logistics tracking
BIM to Database Date: History of status
Real time location Error (RMSE) Is Error accepted?
Panel Dimensions location in BIM
SN Tag ID GUID Name Weight Yes/No (0/1) Current Status Date Status
Marking length width height (X, Y, Z ) coordinates Level, x and y axises (X, Y, Z ) coordinates Error threshold
1 Erected and Installed
2 Erecting and Installing
3 Stored at Storage Area
4 Stored at Storage Area
5 Delivered to the Site
6 Fabricated at Production Source 1
7 Fabricated at Production Source 2
8 In production
9 In production
10 In production
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
RFID handheld readers RFID System at site RFID tags
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
RTK-GNSS system mounted at crane hook block
1. RTK-GNSS system
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Smart Camera system mounted at crane hook block
2 AP Antenna
Camera
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Smart camera day and night views
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
LCD touch screen monitor located at crane cabin Centralized Computer System located at site office
System in the Centralized Computer System located at site office and
the LCD touch screen monitor located at crane cabin
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
LCD touch screen monitor located at crane cabin
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Funded under BCA PIP grant Smart Crane System 0.5
Media Coverage of the Smart Crane System 0.5 in Straits Times, 4 Dec 2016
http://www.straitstimes.com/singapore/smart-crane-for-precast-building
Modification of the Tower Crane (TC6) for Blks 7 &8 of the SIGNATURE AT YISHUN,
the Executive Condominium project constructed by Kimly construction
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Real-time Path Monitoring of precast element hoisting operation
Video capture of smart crane system in tower crane cabin during hoisting of precast panel : B7L11-7-PWAL10007
Monitor inside
crane cabin
Centralized Computer System
19
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Safety Record for the Hoisting Process
Video record of the hoisting process as captured by camera on the crane hook block of smart crane system 0.5
during hoisting of precast panel : B7L10-7-PW5014
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Project Innovations
The main innovations of project/Developed System are listed below.
1. Smart and semi-automated real-time Logistics management and inventory tracking; RFID system integrated with BIM system
and database to track the storage area on site (through scanning the precast elements’ tag IDs and slot IDs by manpower) and
automatically real-time update BIM and database.
2. The proposed safe lifting/hoisting path for each precast element is based on the 6-Key points method developed in this
project, it is generated and shown in BIM environment instantly to guide the crane operator for safe hoisting of precast
element. An algorithm (computer programming) was developed for the proposed method based on the site practice and safety
considerations.
3. RTK-GNSS tracking system with real time correction integrated with BIM system and database was developed to visualize
the precast element in BIM environment while it is hoisting and installing and automatically real-time update BIM and
database, i.e. visualization the actual path of the hoisting and installation of the precast element in BIM environment;
positioning accuracy: real-time pre-designed hoisting path to guide the crane operator to hoist precast elements safely and
install them to positions accurately with desirable precision (less than 20 cm).
4. Installation of wireless video camera system on the crane hook block provides the crane operator inside the tower crane
cabin with real-time visibility of the hoisting process including the hosting locations, flight paths, and final installation at high
floor, this removes the blind spot that tower crane operator is now facing.
Implementation of a Smart and Semi-Automated
Precast Elements Logistics Management and Installation System
Future possibilities
1. The crane operator need not be in the cabin in future to operate the crane; the crane can be remotely
operated by using the proposed system at an e-kiosk located at the construction level (Ground
communication with crane system).
2. With reference to PM comment that how PSA has improved their crane operation with the help of
technology, whereby one crane operator can now operate a few cranes. This could be possibility in future
at construction sites.
BIM Server/Cloud based
Database
BIM SYSTEM
Smart Crane
System
Tower Crane Operator,
e-Kiosk (Cabin) at Construction level
equipped with fixed and mobile remote
control devices and touch screen monitors
Instructions:
Current hoisting Module : B1-L5-Z2-1080
Next Module to be hoisted: : B1-L5-Z3-1090
Touch screen monitor Mobile Remote control device,
Communication at Construction
level with crane system
Architecture of the proposed System Remote control Mechanism for Smart Crane System
PILOT PROJECT
OWNER:
JBE HOLDINGS PTE LTD
ARCHITECT:
DESIGN LINK ARCHITECTS PTE LTD
C&S ENGINEER:
KCL CONSULTANTS PTE LTD
M&E ENGINEER:
RANKINE & HILL (SINGAPORE) PTE LTD
EXECUTIVE CONDOMINIUM PROJECT
CONSISTING OF 11 TOWER BLOCKS WITH
12 STOREYS RESIDENTIAL FLATS AND
1 BASEMENT CARPARK
PROJECT LOCATION
Site location
RESEARCH AREA
Blk 7
PRECAST CONSTRUCTION
RESEARCH AREA
BLK 7 & 8
Total no. of Precast elements for Blks 7&8: 65+ 65= 130 pcs / floor
PRECAST CONSTRUCTION
BLK 7 BLK 8
SITE UTILISATION PLAN
TC 6 for Research Area
PRODUCTIVITY IMPROVEMENT
1
The system has resulted in manpower saving (Manpower and
Man-hours reduction) at each innovation area, i.e. logistics,
inventory checking and hoisting and installation.
2
The developed system helps the tower crane operator
for “heavy” and “blind” lifting.
3
The proposed system transforms the existing process to a systematic
way of precast construction, Automation in Construction.
PRODUCTIVITY IMPROVEMENT
# Action in present process Activities Action in proposed process Improvement
1 Hard Marking as Label, Manual Scheduling and Coordination Using Sensor for precast Saving of 2 manpower,
tracking of elements’ (Sequencing of Precasting elements tracking (ID), system Appx 10-20 %
production, Based on 2D and Precast Elements logistic propose sequence no., based Man-hours saving
Management)
drawings on BIM
2 Hard Marking as Label, Manual Inventory Check (On site) Using Sensor for precast Saving of 1 manpower,
tracking of elements’ storage of Precast Elements elements identification (ID), Appx 30 %
location, Based on Hard Copy real-time integration with BIM Man-hours saving
Print Outs (2D)
3 Manually Operation, 2D based, Hoisting and Installation Sensor, smart camera system, Safe hoisting due to added
rely on manpower decisions of Precast Elements and Positioning System-based visibility provided by camera
(signal man, etc.) system real-time integration and developed system,
with BIM reducing number of “blind lifts”
SMART CRANE IN INDUSTRIAL PROJECT
Future Collaboration - Smart Hoisting for Heavy Precast
Increase the awareness of crane operator through BIM/VDC-based hoisting path planning
integrated with smart video cameras system, sensors and positioning technologies.
BIM SERVER/
CLOUD BASE
SYSTEM
Thank You
Q&A
Dr Meghdad Attarzadeh
Meghdad@ntu.edu.sg
