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1. the happy customer
AND OTHER SHORT STORIES FROM 2011

2. The Happy Customer
Once upon a time, there was a steel plant. Inside the plant the
warm air was heavy with the sounds of industrial production.
Machines and workers labored beneath a curtain of grime. From
the shadows a huge ladle crane slowly lifted its massive load of
scrap metal to the electric arc furnace. A crushing roar and flash
of power transformed the scrap into an orange-hot broth of molten
steel. The workers knew that without the service of the monstrous
ladle crane, the entire facility would come to a standstill.
One frightful winter night, cold and blustery outside, hot and
loud inside, the ladle crane was crippled by the failure of a
component in its operating machinery. Over several months the
maintenance provider had kept things running but had been
unable to make a long-term fix to a recurring problem. The
operations manager had recently heard about Konecranes and
easily made online contact with the local service branch using a
mobile smart phone.
Two days later the plant was in high spirits. Konecranes had
responded quickly, then diagnosed and fixed the problem. Over
the next several weeks Konecranes performed a variety of service
work and offered a number of productivity-enhancing upgrades on
the ladle crane and other lifting equipment.
Two months later the customer agreed to a long-term inspection
and maintenance contract. Gradually things began to change.
Within one year, unplanned downtime had dropped 40%. Fewer
safety-related incidents occurred each month. The company
became more profitable and invested in additional upgrades that
Konecranes had recommended during their Business Review.
Two years later, a second ladle crane is on order. The plant’s
maintenance area has two workstation lifting systems.
The original ladle crane is running much more reliably after
Konecranes used RailQ and CRS to uncover some problems that
were not previously known.
The customer is very happy.
The End.
(Note to reader … this story is fictitious, but could be perfectly real. All of
the other stories in this booklet are actual events and real customers.)

3. Mission Table of contents
NOT JUST LIFTING AEROSPACE
Teledyne Technologies, Inc................ 7
INTERMODAL
Union Pacific Railroad..................... 33
THINGS, BUT ENTIRE NASA’s Glenn Research Center.......... 8
A Leading Aerostructure
A Midwest Locomotive Shop............ 34
BUSINESSES Manufacturer.............................. 10 MINING
An Underground Mining Equipment
ALTERNATIVE ENERGY Manufacturer.............................. 37
Brithinee Electric............................ 11 A Mining Machinery Company.......... 38
Resort Municipality of Whistler........ 12 A Mining Equipment Manufacturer..... 39
Vision A Leading Mining Manufacturer....... 40
AUTOMOTIVE
“We know in real time how millions of lifting A Midwest Diesel Engine OFFSHORE
devices and machine tools perform. We use Manufacturer.............................. 15 Elevating Boats, LLC....................... 43
A Weld Tool Center.......................... 16 National Oilwell Varco..................... 44
this knowledge around the clock to make our A Southern Manufacturing
GENERAL MANUFACTURING
customers’ operations safer and more productive.” Bauer Manufacturing, Inc................ 17
Company.................................... 46
Link-Belt Construction Equipment POWER
Company, Inc.............................. 18 BC Hydro, Mica Generating Station.... 48
A Leading Construction Equipment R.E. Ginna Nuclear Power Plant....... 50
Values
Manufacturer.............................. 19
Trust in People U.S. Concrete................................. 20 PULP & PAPER
Liberty Paper, Inc............................ 54
We want to be known for our great people. A Leading Construction Equipment
Manufacturer.............................. 21 Weyerhaeuser Paper Mill................. 56
Alaskan Copper & Brass................. 22 STEEL
Total Service Commitment Novelis........................................... 24 An Integrated Steel Plant................ 59
We want to be known for always keeping An Integrated Aluminum Facility....... 25
Westfield Industries........................ 26
Johannessen Trading Company....... 60
A Leading Steel Company................ 61
our promises. Limbach Company.......................... 28 EMJ Metals.................................... 62
HARBORS & SHIPYARDS A Leading Steel Manufacturer......... 64
Sustained Profitability APM Terminals................................ 30 A Steel Manufacturing Plant............ 66
We want to be known as a financially
sound company.
Strategies
> Differentiation through service
and technology innovation
> Lifting people
> Global footprint and supply chain
> Dual-channel For the most current
customer stories, go to
> Real-time information www.konecranesamericas.com/
customerstories

4. 7
Teledyne Technologies, Inc., Huntsville, Ala.
KNOWLEDGE, commitment AND Reliability
increase uptime AND minimize cost
challenge
Relocation and repairs
Alabama-based Teledyne specializes
in full-spectrum engineering and
advanced manufacturing. It operates
in the complex and demanding
industries of aerospace, missile
defense and nuclear energy, serving
both government-supporting and
commercial customers.
When faced with a large relocation
and repair project, Teledyne Director of Manufacturing Operations, Jeff
Holley knew just who to call. “I needed a service partner who could face
the challenge, keep the delivery schedule and be capable of handling
complex machinery and hardware,“ Holley recalled.
SOLUTION
Expert knowledge of complex parts
The scope of the project included the relocation and repair of small-, medium-
and large-sized machines with very sophisticated parts, such as highly precise
5-axis CNC machines. A team of 10-12 Konecranes Machine tool Service (MTS)
engineers and specialists was responsible for the three-month relocation
project including, but not limited to, new foundations, modernization, material
handling, machine installation, debug, alignments and laser calibration.
Due to the complexity of the parts and the special materials and processes
used in the Teledyne products, skilled Konecranes personnel were
essential in completing this project.
RESULTS
Completed on time and within budget
As a result of proper planning and effective project execution, the
relocation and repair project was completed within budget and one week
ahead of schedule. Teledyne and Konecranes MTS are currently discussing
expanding the cooperation between the two companies. Konecranes MTS
Key Account Manager Harold Schoch explains, “We simply want to be
viewed as indispensable to our customers’ success.”
“There were no surprises. MTS
clearly understands the needs of
our machines and gives a complete
analysis and detailed cost estimate.”

5. 8 9
NASA’s Glenn Research Center, Sandusky, Ohio
UNIQUE CUSTOMIZATION SAVES
CUSTOMER TIME AND MONEY
AN ARRAY OF CHALLENGES The original crane system was limited in its ability to provide accurate and
A variety OF SOLUTIONS precise movements, and had no way to detect whether a load was too
Outer space environment simulation heavy or still bolted to a test fixture. This challenge was overcome with the
chamber imposes harsh demands retrofit of a load measuring device integrated with the crane controls.
on earth-bound metal, lubrication Because of the sheer size of the spacecraft components being
and wiring. suspended for testing, NASA’s engineering team was keen to gain
At NASA’s Glenn Research Center precise control in making critical positioning adjustments—a function the
Plum Brook Station in Sandusky, 1960s technology did not provide. Therefore, Konecranes recommended
Ohio, the Space Power Facility (SPF) variable frequency drives, plus enhancements to provide both inching and
is home to the world’s largest space microspeed functions.
environment simulation chamber
– 100 feet in diameter by 122 feet RESULTS
high. The dome-capped vacuum chamber is used to test large, space- Advanced technology from Konecranes saves time,
bound hardware within a simulated environment of outer space. enhances safety and improves critical positioning.
Selection of new materials and technologies, combined with clever
To hoist, position and stabilize spacecraft components prior to testing, engineering design, saved this important customer time and money, while
the test chamber is outfitted with a modified polar crane, with the bridge improving safety and functionality.
spanning the radius of the area similar to the hands on a clock. Originally
built from state-of-the-art systems, controls and materials, numerous
upgrades became necessary after nearly 40 years of use.
The extreme negative pressure in the vacuum chamber causes outgassing,
a condition where compositional molecules, including dirt, oil and grease,
are released from substances present in the vacuum environment. These
molecules can stick to the surfaces of spacecraft, which must be kept
meticulously clean. The crane is constructed of aluminum, which has very
low outgassing properties. Outgassing also affects bearings, wiring and
insulation in the control panels, all of which require special materials.
With typical control panel wiring, every time NASA readied the chamber
for a vacuum test they would need to remove the entire control panel from
the crane—which weighs several thousand pounds. Instead, Konecranes
engineers used Teflon® wire, allowing the majority of the controls to remain
in place during simulation events.
Certain elements within the control panel, including the inverters, were
designed to be removable prior to initiating a vacuum test. Previously,
it would take up to several days to remove components with outgassing
properties, whereas this new system was designed to enable their removal
in a matter of hours.

6. 10 11
A Leading Aerostructure Manufacturer Brithinee Electric, Colton, Calif.
Konecranes MTs diagnosed and INCREASED CRANE CAPACITY
fixed a long-standing problem, HELPS FACILITY MEET DEMANDS
reducing processing time by 60% OF ALTERNATIVE ENERGY
and saving $300k per year challenge
CHALLENGE Increased demand,
Too much scrap more cranes needed
A leading global manufacturer Brithinee Electric in Colton, California
of aerostructures, located in the specializes in the repair of industrial
southern United States, builds electric motors and wind generators.
aircraft components such as They needed additional space and
stringers, ribs and spars for the increased crane capacity to work on
aerospace industry. the large electrical units used in the
wind industry, their fastest growing
Before Konecranes Machine Tool market segment. Brithinee Electric is
Service (MTS) was contacted, an within 125 miles of two of the largest wind farms in the United States. With
old but critical machine in the facility produced an unacceptable quantity of demand for alternative energy increasing, the company needed to expand
scrap parts, thereby wasting costly raw materials and valuable processing to be able to meet the demand.
time. Scrap from the machine in question totaled $300,000 the previous
year and $160,000 year-to-date. In 2004, Brithinee Electric began planning an expansion of their workspace
by almost 20,000 square feet.
SOLUTION
Upgrade controls, motors and drives SOLUTION
For over a year and a half, the maintenance department and the original Konecranes identifies crane needs
equipment manufacture could not determine what was causing the scrap Brithinee Electric’s crane selection involved acquiring dimensions for
parts to be created. Konecranes MTS was able to properly identify the machines they had never seen, including overall dimensions as well as
problem during the initial visit. weight. Konecranes helped steer the selection based on cranes generally
used in manufacturing plants in the wind industry.
Because Konecranes MTS Service Engineers had proven themselves
with a fast response time to a service need, they were awarded a Konecranes developed several different concepts and layouts for Brithinee
modernization through retrofit. Konecranes compared the machine‘s Electric’s new facility. The two companies and the project engineer worked
current performance against matching statistics when it was new, together to determine the best solution for Brithinee Electric’s needs,
uncovering an unfavorable variance. including how the geometry of the cranes’ structures (bridge length,
dimensions between uprights, etc.) would affect price.
Based on the results of this assessment, Konecranes MTS proposed an
upgrade with new CNC controls, motors and drives via retrofit. After several collaborative revisions to the plan, Konecranes ended up
installing a 20-ton crane, a 10-ton crane, a 5-ton bridge crane and a jib crane.
RESULTS
Less scrap and 60% reduction in processing time RESULTS
The Konecranes MTS team has become essential to helping the facility Production levels doubled with new cranes
manufacture quality parts and reduce processing time. Konecranes The larger facility and the new cranes have allowed Brithinee Electric to
MTS reduced the processing time for some of the components by 60%. double its production of wind generator and large motor repair. Konecranes
In a competitive bid process, the aerostructure manufacturer awarded also continues to provide service to Brithinee Electric’s cranes, ensuring
Konecranes MTS a gantry mill retrofit project. increased uptime.
“The new building delivered a WOW FACTOR,
AND THE CRANES ARE A KEY INGREDIENT OF THAT.”
Wallace P. Brithinee, Brithinee Electric

7. 12 13
Resort Municipality of Whistler, BC, Canada
TURNING MUNICIPAL GARBAGE
INTO MARKETABLE COMPOST
WITH an OVERHEAD CRANE
challenge weigh each load it picked up, which
Electric overhead crane needed to move and load compost helped standardize the product.
The Resort Municipality of Whistler is a community of 14,000 permanent
According to Patrick Mulholland,
residents whose Whistler 2020 vision for environmental sustainability is
Compost Operations Manager at
one of the most aggressive in North America. Whistler annually welcomes
Whistler, another good decision was
around 2 million guests for winter and summer sports, but due to terrain
to let Konecranes Service maintain
limitations and a plentiful bear population that rule out a landfill, options
the crane with quarterly maintenance
for nearby waste disposal are limited.
inspections with a heavy emphasis on
With exporting its garbage to the state of Washington as the only alternative, preventive measures. “The crane is a
Whistler committed to build a new $14 million regional composting facility. sophisticated piece of machinery. We
Since a prior composting pilot project at a nearby industrial park in Squamish were happy to let Konecranes take
resulted in an odor issue, all planning parties agreed that the material care of the crane so that we could focus on other parts of the process.”
handling methods for the new facility would need to evolve.
RESULTS
One of the major issues identified in the Squamish pilot project was the Composting facility receives clear return on investment
front-end loaders burning fossil fuel, which resulted in fumes and exhaust Whistler has begun to get a clear picture of their return on investment in
inside the building. They also tended to track biosolid residue all over the the regional composting facility and the crane. The crane reliability has
site, creating a very dirty environment. Therefore, a decision was made to been extremely important to the project.
replace them with an overhead crane to move and assemble the primary
ingredients for compost. “Without the crane functioning, the plant does not function. Without the
plant functioning, our ability to deal with biosolids locally comes to a
In addition to sustainability, the crane criteria included best possible complete halt. We have the capacity to receive biosolids for only two to
reliability, proven technology and the ability to call in local service contacts three days before we have to ship it to Washington State at a significant
in case something went wrong. cost,” says Ron Sander, Whistler Environmental Operations Manager.
SOLUTION The benefits of the overhead crane have also included the elimination of
Five-tonne bucket, 2.5 m3 grab, DynAPilot anti-sway and automation diesel fumes in buildings and confined areas, allowing doors to be kept
Based on Konecranes recommendation from Konecranes, a five metric ton closed and thereby minimizing the escape of odors and dust.
bucket crane, operated by electricity, was selected for biosolids handling.
“Whistler is very pleased about the short and long-term benefits our new
The 18-meter operating span with a 2.5 cubic meter hydraulic grab was
composter brings,” says Whistler’s Mayor Ken Melamed. “Composting
suitable for a small-scale facility and allowed efficient use of floor space
reduces export waste, treats multiple waste streams locally, produces
and easy access to all stored materials.
revenue-generating by-products and saves money for the taxpayers and
The crane is radio controlled and equipped with DynAPilot anti-sway load local businesses. The question is why we did wait so long?”
control software. It was set up for future automation, though it was decided
to have a human running the process, allowing the mixture to be tweaked
for changing temperature conditions and pick out unwanted items to
maintain quality control in the compost. The crane also had the ability to “There were reservations from experienced operators
on the design of using a crane rather than loaders. Now,
we’re in agreement that it has been probably the most
pleasant surprise of the project – just how well that
crane has worked.”
Ron Sander, Whistler Environmental Operations Manager

8. 15
A Midwest Diesel Engine Manufacturer
CUT ANNUAL equipment costs
in half with scheduled inspections
challenge
Production demands
exceeded capabilities
A Midwest diesel engine
manufacturing plant manufactures
diesel engines for consumer pickup
trucks. Due to the competitive nature
of the diesel engine industry, the
company is constantly looking to all
areas of production to cut costs and
increase efficiencies.
The manufacturing plant was constructed in 1971. It originally built
components such as pistons, connecting rods, pulleys, rocker housings
and water pumps. In the early ’90s, the plant was converted to an engine
production plant. Production demands have escalated ever since.
Like other plants of its kind, it is producing numbers well beyond the
plant’s original capacity. Therefore, downtime is not an option.
SOLUTION
A planned approach to repairs, replacements and spare parts
This Midwest diesel engine manufacturing plant has long focused on their
core competency–building engines. They have relied on Konecranes to
take care of their 120 hoists and cranes for over 15 years. In an effort
to extend the life of the plant’s overhead lifting equipment, Konecranes
identified the highest usage cranes and set up a maintenance plan for
the cranes selected.
The plan included replacing out-dated equipment, rebuilding older “work-
horse” hoists and establishing a structure for repairs. This allowed
for repairs to be completed as they were identified during inspections,
eliminating potential downtime from unexpected breakdowns.
RESULTS
Per unit cost decreased 50%, excellent safety record
By collaborating with Konecranes and sharing expertise, the annual cost
per unit has decreased 50% from 2005-2009 with no additional downtime.
Since this maintenance plan has been put into effect, there have not been
any crane-related injuries or incidents at this manufacturing plant.

9. 16 17
A Weld Tool Center Bauer Manufacturing, Inc., Conroe, Texas
Comprehensive preventive maintenance Customized and reliable produCt
plan puts customer at ease design puts Customer at ease
CHALLENGE challenge
In-house maintenance Growing company
unable to meet demand requires more cranes
In the Midwest, a weld tool center Bauer Manufacturing, Inc. is an
for a major automobile company international provider of services,
engineers the robotic weld tools that machinery and ancillary products in
assemble the body structure of a the earth-working and groundwater
vehicle. Over 200 cranes are used at fields, operating under three industry
this facility, from 1-ton chain hoists segments including construction,
to 50-ton cranes, as well as jib and equipment and resources.
gantry cranes.
Based in Germany, this 200 year-old
The in-house maintenance team was overwhelmed with the crane service company expanded to North America in 2008. Bauer’s first manufacturing
needs of the facility. Because service and repairs were not performed headquarters in North America is located in the Conroe Industrial Park in
consistently, the maintenance records were not kept up-to-date. The weld Conroe, Texas. The campus sits on 80 acres and is being built in phases.
tool center needed a company capable of providing service and preventive
The first phase is over 200,000 square feet. When Bauer started
maintenance for all of their cranes.
to design and build phase one, they turned to Konecranes for their
SOLUTION overhead lifting needs.
Maintenance outsourced to Konecranes
SOLUTION
Out of several competing offers, Konecranes stood out as the clear Konecranes provides specialty lifting equipment
choice to be the sole provider for crane maintenance. The company has
Konecranes was chosen as the provider of Bauer’s eight overhead cranes
outsourced 100% of their crane work to Konecranes. The cranes have
and two Rubber Tire Gantry cranes. Konecranes offers state-of-the-
been repaired and now are performing up to standard. Quarterly and
art, high quality products at competitive prices. Because of their price
annual inspections help to proactively determine problems before they
competitiveness and their follow up with sales and service, they were
happen, and monthly preventive maintenance helps keep the cranes in
awarded the job.
top condition.
Bauer had specific needs for the use of the cranes. Konecranes was able
A technician is on site five days a week to do repairs and cover
to work with upper management to design cranes that would fit their needs.
breakdowns. With a strong maintenance team to depend on, the in-house
maintenance team no longer needs to track crane inspections, repairs, RESULTS
breakdowns or expenditures. Quality products and service satisfy the customer
Bauer Manufacturing is very pleased with Konecranes and the sales and
RESULTS
service team. With the expansion of Bauer Manufacturing in North America,
Konecranes Circle of Compliance in place,
there are plans to install many more Konecranes products in other facilities
satisfied customer purchased eight more cranes
in the near future.
The customer continues to follow the business plan and benefit from the
Circle of Compliance – to inspect, repair and maintain.
“We feel comfortable that our Konecranes cranes
Based on the successful relationship between the companies, a sister will give us good service well into the future.”
plant recently purchased eight new cranes from Konecranes.
Bauer Manufacturing

10. 18 19
Link-Belt Construction Equipment Company, Inc., Lexington, Ky. A Leading Construction Equipment Manufacturer
Deep expertise results Remanufactured Machine
in a win-win situation Increases Uptime and Productivity
CHALLENGE while Enhancing Safety
Increased production levels CHALLENGE
call for machine upgrades and Increased demand called for a new machine
modernizations
A leading construction equipment manufacturer produces parts and
The Link-Belt Construction Equipment components for construction and power generating equipment. Their
Company is a leader in the design, production process requires special machine tools for facing pockets.
manufacture and sales of telescopic These “pocket facing” machine tools are used to cut the smooth, flat
and lattice boom cranes. Their surfaces where the bearings for planetary gears are mounted. Market
headquarters are in Lexington, Ky. demand increased beyond the capacity of their critical path machine
Link-Belt’s core production base and center for worldwide operations is its tools. They sought a qualified machine tool service team to identify a used
500,000 sq. ft. manufacturing facility. machine tool that could be redesigned and modified to produce the proper
part accuracies and finishes required for pocket facing applications.
To support their expansion plans over the last 10 years, Link-Belt brought
in Konecranes Machine Tool Service (MTS) to provide technical assistance SOLUTION
and expertise to solve their machine challenges. A refurbished machine met the challenge
With the experience of rebuilding, remanufacturing and retrofitting over 170
SOLUTION machine tools for this construction equipment manufacturer, Konecranes
Modernizations performed on diverse machines Machine Tool Service (MTS) had the technical expertise necessary for the
In years past, Konecranes MTS had provided many solutions to Link- project. After a careful review and thorough inspection, a used vertical
Belt’s machine challenges. Their large Cincinnati-Gilbert Floor Mills were machine with a pallet changer was chosen. The pallet changer reduced
mechanically overhauled and retrofitted with a Fanuc control system. “The overall set-up time as parts could be put on the fixture of one pallet while
personal delivery of the Mitsubishi special head spindle was appreciated. the machine was cutting a different part on another pallet.
You felt this urgency as if you were in my shoes here,” said Bowman to
Harold Schoch, Key Account Manager of Konecranes MTS. A customized head was added to generate the pocket facing cuts. Due
to the fixture height and the size of the generating heads required for
Konecranes MTS performed a complete geometry overhaul of a Giddings the part, a riser was designed and installed underneath the machine’s
& Lewis 60, the full contouring table rebuild of a Cincinnati T-40 HBM and column in order to provide enough height for machining the part. The gib
the complete restructure of the long “X” axis on a smaller Cincinnati-Gilbert and clamping system of the machine was re-engineered to increase the
boring mill as well. machine’s strength, dampen vibrations and make it easier to perform
“Your help with our Cincinnati-Milacron, the recent help with the double maintenance work.
gantry boring mill head, the Giddings & Lewis 60 and the Wotan Cutmax 2 A new chip collection and conveyor system with guarding was installed to
have proven to Link-Belt Senior Management that your staff can work on protect the machine and further reduce the overall maintenance needs
diversified machining equipment without concern,” Bowman commented. for the machine. A full enclosure that included door safety interlocks, that
RESULTS was not incorporated on the original machines, was designed to further
Completed on time and within budget enhance operator safety.
“Konecranes MTS continued commitment to quality, attention to meeting RESULTS
the customer’s deadlines and coming in on budget continues to make your Enhanced part accuracies, safety and productivity
company the first in mind when support is needed on our machine tools,” The machine run off tests showed that the remanufactured machine was
continued Bowan. capable of providing the part accuracies and finishes required for pocket
facing applications while enhancing safety and productivity.
“This Cincinnati-Gilbert machine
has worked well for us and was an
example of your team’s expertise.”
Link-Belt Construction Equipment Company, Inc.

11. 20 21
U.S. Concrete, San Diego, Calif. A Leading Construction Equipment Manufacturer
Customized installation, Quality parts and precise
deCreased ConstruCtion engineering eliminate downtime
Costs and inCreased CapaCity CHALLENGE
challenge Quality and productivity
Designing a new facility In the Midwest, a leading construction
U.S. Concrete serves the construction equipment manufacturer produces
industry with concrete and precast/ medium speed diesel engines for
prestressed concrete products. electric power, locomotive and
industrial applications. As an
As a satisfied customer of Konecranes for integral part of the manufacturing
over 10 years, there was no question whom process, machine tools are used
they would turn to when they were building to bore holes and provide smooth
a new plant. “We wanted a design that was finishes to the engines.
efficient, well laid out, on time, and of course
offered value overall,“ said Todd Ebbert of One of their critical machine tools contained outdated controls, motors
U.S. Concrete. “Before we settled on this new and drive amplifiers. The aged components caused control-related failures
facility, we looked at different options at existing sites and Konecranes helped that stalled production at the facility. Every moment the critical machine
us design and configure various options for each one.” remained out of service cost the facility expensive amounts of downtime.
The machine needed to be updated with more reliable components in order
SOLUTION to meet projected demands.
Customized cranes and layout assistance
The new facility would be built on an 18-acre site. The precast concrete SOLUTION
manufacturing would be performed in an 80,000 sq. ft. building. The facility Collaborative repairs with the OEM
was designed for two large crane bays. These crane bays would be served by A collaborative effort was needed to ensure the best results in the shortest
10 total overhead bridge cranes with capacities ranging from 5- to 50-ton. amount of time. The construction equipment manufacturer needed a supplier
with a comprehensive range of technical experience that could effectively
It was a concern that the building walls would not be able to support the work in concert with the original equipment manufacturer (OEM) and the in-
largest crane’s full capacity of 50-ton. Konecranes suggested that the center house repair team to make the necessary repairs and improvements.
40’ span of the 80’ bridge crane would lift the full capacity of 50-ton while
the outer 20’ of the span to either side would be limited to 30-ton capacity. Konecranes Machine Tool Service (MTS) was selected due to their unique
This effectively reduced the load on the walls, and in addition, decreased skill sets and access to a comprehensive supply chain for spare parts.
construction costs. Konecranes provided technical support as well as Konecranes MTS calibration technicians were able to optimize the machine’s
innovative ideas to keep the project cost-effective while meeting all of the geometry and positioning using Hamar and Renishaw laser systems.
customer‘s needs. Two cranes from the old facility were brought to the new RESULTS
site. Konecranes modified these cranes to meet the new facility requirements. Downtime brought under control, quality increased
RESULTS Konecranes MTS Service Engineers eliminated the downtime caused by the
Customer pleased with crane system and performance aged machine tool components. The mechanical and geometrical repairs
The facility as well as the crane runway system were built to schedule and that Konecranes MTS made increased the quality of parts the facility
completed from start to finish in less than a year. “The crane system has produces. The collaborative effort with the in-house repair team and the
performed exactly as expected and we are very pleased with the results. OEM decreased the amount of time required for the machine to be put back
We have converted a couple of the cranes to wireless pendants and may into production. Based on the success of this project, Konecranes MTS will
convert all of them in the near future,” said Ebbert. continue to work alongside the customer on all future shutdown projects.
“Our long term relationship with Konecranes
has benefitted us with the latest advances
in technological and safety aspects for our
lifting requirements.’’
Todd Ebbert of U.S. Concrete

12. 22
Alaskan Copper & Brass, Kent, Wash.
KONECRANES CXT CRANES AND MAINMAN®
INSPECTIONS REDUCE MAINTENANCE COSTS BY 60%
CHALLENGE a month on a regular schedule. A
Taking old cranes to a new location parallel program for inspecting the
Alaskan Copper & Brass Co. was under-hook devices has also been
moving a large part of its operation implemented. Konecranes takes
from Seattle and Renton to a care of significant repairs, while
facility in Kent, Wash. The company minor issues are handled in-house.
needed new lifting equipment and “In the first year, we spent a good
also wanted to relocate some bit of money resolving long-term
older cranes at the Renton facility, problems with the older cranes, but
not purchased from Konecranes. since then our maintenance costs
Alaskan Copper owned a total of 138 have gone down by around 60%,”
cranes as well as about 50 different types of under-hook devices. Most of says Eagle Hilton. “The biggest
them were being maintained in a reactive mode, with repairs occurring only benefit is that downtime, and
when something stopped working. significant breakdowns have been
SOLUTION drastically reduced. Now, we prefer
Some cranes relocated, others purchased to maintain equipment at more
new, all maintained with MAINMAN® optimum levels. With our new policy
In Phase I of this operation, Alaskan Copper purchased two 5-ton single- of outsourcing of maintenance for
girder CXT cranes from Konecranes and asked Konecranes to remove four critical equipment like forklifts and
older cranes from the Renton facility, modify them and move them to Kent. cranes, we’re down to one in-house
This process went well, and Eagle Hilton, Alaskan Copper’s new mechanical electrician at this facility.”
project coordinator, retained Konecranes to begin monthly inspections
of all of its cranes using MAINMAN®, a multi-point visual inspection. “We are truly satisfied with every aspect of service
MAINMAN® inspection captures data on the condition of over 225 crane we’ve received from Konecranes. Companies like yours
components and then analyzes, prioritizes and schedules required repairs make companies like ours better and stronger, not to
in compliance with local statutes and laws. mention making my job a lot easier.”
Eagle Hilton, Mechanical Project Coordinator, Alaskan Copper
In Phase II, Alaskan Copper purchased four more 5-ton double-girder CXT
cranes, and also asked Konecranes to provide and install over 700 ft. of
runway for the new cranes in an existing building. The configuration of the
long bay runway allowed offloading of product into smaller bays running
perpendicular to the runway.
RESULTS
Effective sharing of responsibility with in-house
teams, maintenance costs down 60%
When the inspection program began, Konecranes technicians were working
on the older cranes weekly. But one year later, as larger issues revealed
by the inspections were resolved, Konecranes inspects just 15-18 cranes

13. 24 25
Novelis, Oswego, N.Y. An Integrated Aluminum Facility
HIGH QUALITY, COST EFFECTIVE PREVENTIVE MAINTENANCE SAVES
PRODUCT INCREASES PRODUCTIVITY OVER $45K USD IN REPAIRS ANNUALLY
challenge CHALLENGE
Unreliable radio controls stall production No challenge yet ...
Novelis, in Oswego, N.Y., is the global leader in aluminum and beverage Konecranes keeping in touch
can recycling. They produce an estimated 19% of the world’s flat-rolled with a potential customer
aluminum. Cranes are a critical part of the rolling, casting and fusing An integrated aluminum and
manufacturing processes and are used to transport sheets of aluminum. smelting facility, located on the
east coast, is one of the longest
The radio control systems they used to operate their cranes began
continually operating aluminum
to malfunction. Without a reliable way to maneuver their cranes, the
facilities in the world. Its products
manufacturing process stalled, resulting in expensive downtime.
serve the automotive, industrial, and
SOLUTION aerospace industries. Their cranes
Effective radio controls allow operators range in size from 10-50 tons and
to be mobile, productive and efficient are used to handle molten metal and
Out of two other proposals, the Cervis/Ikusi Hand Held and Belly Belt to transport the finished product.
radio controls proposed by Konecranes stood apart as the highest quality Seven years ago, the integrated aluminum facility handled all crane
products at the most cost- effective price. The controls have a heavy duty maintenance work internally. After three years of contacting the company,
customized transmitter, a category level 3 safety rating, long battery life, Konecranes was able to arrange a meeting to discuss benefits of the
fast chargers and position selector switches that either maintain position MAINMAN® preventive maintenance program. They liked the idea of a proactive
or force return to the 0 position, which allow operators to be safe, mobile, plan for inspections, repairs and maintenance, but because they had an in-
productive and efficient. house crane maintenance team, they did not have a need for it at that time.
The first few radio controls that were installed worked effectively and did SOLUTION
not cause downtime. Since then, over 75% of the plant’s cranes have been An occasion to inspect revealed numerous opportunities for repair
switched over to Cervis/Ikusi radio controls.
The next year, the integrated aluminum facility called Konecranes with
RESULTS an urgent need for a complete inspection to be performed on one of
Additional Smart Solutions added over time their cranes. Many of their other cranes were experiencing frequent
After proving themselves with the radio control project a decade ago, breakdowns as well. The technicians completed the emergency inspection
Novellis trusted Konecranes to increase their productivity in other areas. and submitted a comprehensive MAINMAN® report which included a
Currently, Konecranes is developing an anti-collision system for two levels detailed assessment of the crane. The integrated aluminum facility was so
of cranes – one crane on the high bay and two cranes on the lower bay. impressed with the crew and the quality of their work that they turned over
The cranes will coordinate their positions use Smart Solutions technology, 15 more of their cranes for the same process. The inspections showed
which helps prevent collisions. that many cranes were not up to code. Konecranes was asked to complete
all of the repairs in a process that took two years to complete.
The anti-collision system ensures that the crane on the high bay will not go
over the cranes in the lower bay while holding a load. Smart Solutions Anti- RESULTS
Sway technology is being added to three of their cranes. By preventing the load Overall savings of $45,000 per year
from swinging during crane travel, the operator does not have to divide their After the extensive repair process, the cranes are in better overall
attention from controlling the crane movements and monitoring the load itself. condition. Konecranes has an annual contract for inspections and
planned maintenance. The amount of downtime and unplanned repairs
has decreased significantly at the plant. The integrated aluminum facility
now saves over $45,000 USD annually in inspection and preventive
maintenance costs compared to prior years. Konecranes also performs
preventive maintenance and has a site contract on all of the below-the-
hook devises at other areas of the work site.

14. 26
Westfield Industries, Manitoba, Canada
MANUFACTURING CAPABILITY
AND SPECIAL INSTALLATION
MEETS CONSTRUCTION DEADLINE
CHALLENGE
New plant needed open plan and space flexibility
Westfield Industries has been manufacturing grain augurs
for over 50 years. Their simple, straightforward design,
ease of operation and labor-saving performance have made
Westfield the number one portable grain augur manufacturer
in the world. This success spurred development of a new
manufacturing facility near Winnipeg. Westfield’s design the roof open for a traditional, straightforward install. Konecranes was
team wanted a completely open span inside the building for responsible for taking the measurements and forging a plan to install the
maximum flexibility. 105’-long girders after the building was closed in.
Westfield didn’t want machines permanently sited anywhere— RESULTS
they wanted to be able to reposition equipment as needed Customer satisfied with “flawless” installation
as augur designs evolved. For that to work, they required two Konecranes was not only responsible for installation, they also took care
new cranes that could span the entire building. Manitoba-area of all of the challenges of transporting the two 105-foot cranes from
lifting suppliers were unable to provide a cost-effective solution Edmonton using a special bogie wheel arrangement on a highway tractor
for the cranes with the 105-foot span the design called for, as trailer rig. According to Wilcox, everything went according to plan. “We had
their facilities were not set up to be able to manufacture the a great relationship, and the project worked out very well. We had a good
large and long box girders required. Westfield was faced with thing going with the installation—it went flawlessly.”
the possibility of having to split the shop into two 52’ sections
and install a third, central runway with cranes on each side of
the building. “Konecranes was much more professional than the
other bidders and gave us confidence they could
SOLUTION achieve our goals.”
3-ton double girder cranes with 105-ft span Brian Wilcox, Process and Quality Engineering Manager
Westfield’s Process and Quality Engineering Manager Brian
Wilcox contacted Konecranes for a proposal on two 3-ton
CMAA class C CXT double girder cranes with a 105-foot span.
Not only was Konecranes able to manufacture the cranes with
exceptionally large and long girders in their Edmonton factory,
they were also unfazed by a demanding construction schedule.
Westfield had only a short window of opportunity to complete
the building before the rainy season and could not leave

15. 28
Limbach Company, Laurel, Md.
CUSTOM INSTALLATION OF
CXT CRANES AND RUNWAY
SMOOTHS TRANSITION FOR CUSTOMER
challenge
Strict time schedule
to install cranes and runway
The Limbach Company was moving
into a new building specifically
tailored for its specialty piping
business in the Washington D.C.
metro area, and time was of the
essence. Limbach’s capabilities
include HVAC piping and plumbing, stainless steel specialty piping, design
build and energy retrofit/management systems.
Limbach planners needed two new cranes and a new runway, and planned
to move one of their existing 5-ton cranes into the new facility. All the cranes
and new runway had to be installed during several specific time windows in
order to be in sync with the completion of the rest of the building.
SOLUTION
Successful and timely installation working around other trades
Limbach’s Trade Manager Robert Davis contacted Konecranes for a
proposal on two 2-ton CXT cranes, relocation of the existing 5-ton crane
and engineering and installation of 240 feet of runway. “Our timeframe put
them in a bit of a pickle because our construction people were installing
drywall while Konecranes was building the runway,” says Davis. “However,
everything went off without any problems whatsoever. Those guys did a
tremendous job and were just very professional. Things went so well that I
would recommend them to anyone looking for an overhead crane.”
RESULTS
Excellent crane performance enhances productivity
A year later, Davis is still pleased with his CXT cranes, which have given
him “no trouble at all.” Both of the cranes are performing exactly as
promised. The impressive list of operating benefits that they deliver
includes improved rope life, and fast, accurate load positioning. And, the
reduced hook dimensions create more usable workspace. Compared to
older hoist designs, CXT cranes can operate closer to walls and lift loads
higher. For new facilities like Limbach’s, CXT improves flexibility for factory
layout and material flow planning, and enables use of a smaller building
shell that is less expensive to build.
“we appreciate having a subcontractor that
performed as well as Konecranes did. It was a
positive and enjoyable experience for us.”
Robert Davis, Trade Manager, Limbach Company LLC

16. 30
APM Terminals, Elizabeth, N.J.
Current and Potential
Repairs identified to Keep
Port Cranes Up and Running
CHALLENGE analysis of each crane, repair priorities, and a suggested schedule of
More complete required repairs in compliance with local statutes and laws.
crane analysis needed
RESULTS
Nearly 4,500 containers a day
Preventive maintenance saves time and reduces warranty work
pass through the gates at APM
Terminal’s 380-acre Port Elizabeth Because of the MAINMAN® inspections, APM has found that they rarely
facility in Elizabeth, N.J. The terminal have to call Konecranes for warranty work or troubleshooting. Instead, they
processes anywhere from 550,000 use the crane summary reports as a guideline for their maintenance crew
to 763,000 tons of containerized to use in mapping out their workload.
cargo annually. To handle the “We have 30 mechanics to look over 32 RTGs, 19 top loaders, 10 empty
transfer of these massive containers handlers, payloaders, snow removal equipment, manlifts, and large
from ship-to-shore and back, the facility built a fleet of 30 Rubber Tire forklifts,” APM says. “It works out to be about two machines per man, so
Gantry (RTG) cranes from Konecranes. we always keep busy. We don’t have the time to do the fine-tooth comb
APM facilities are required by OSHA Maritime regulations to have an OSHA- inspections that Konecranes does for us.”
certified inspector examine their cranes annually. However, the basic In addition to saving time, the inspections have also caught small issues
safety check performed in compliance with OSHA did not provide the Port and brought them to the maintenance manager’s attention before they
Elizabeth facility with sufficient critical information about the mechanical, became major problems.
structural, and electrical aspects of each RTG crane.
SOLUTION
Comprehensive MAINMAN® inspections “It saves us time because we
With each RTG crane costing nearly $1.5 million, the Port Elizabeth do preventive maintenance
facility chose to invest in Konecranes MAINMAN® inspection services to checks on the machines based on
help prolong the lifespan of each crane and maximize their investment. Konecranes recommendations.”
The OSHA inspection takes one technician about 1.5 hours per crane to APM Terminals
complete. Konecranes MAINMAN® inspection takes three technicians
working eight hours per crane to complete.
That translates into a team of 15 Konecranes inspectors working on-
site for up to three weeks. MAINMAN® requires a substantial amount
of time because they capture data on the condition of more than 225
crane components. Konecranes certified inspectors evaluate hundreds
of component parts and draw on thousands of hours of training and
experience to analyze wear patterns. The results include a detailed

17. 33
Union Pacific Railroad, North Platte, Neb.
PREVENTIVE MAINTENANCE AND INSPECTIONS
LEAD TO TOTAL COST SAVINGS
challenge
Unreliable crane performance
Union Pacific Railroad (UPRR) helps link production and consumption points
in the U.S., and across the world, with a network to deliver the energy, food,
raw materials, durable and consumer goods to support the nation’s growth.
The North Platte shop inspects, repairs and/or provides maintenance
to UPRR locomotives 24 hours per day, seven days per week. Services
include: change outs of power assemblies, traction motors, alternators,
turbos, engine blowers and electrical equipment. They can perform
these services on 12 locomotives at one time. North Platte averages six
complete extensive locomotive inspections per week. Their eight critical
cranes, a variety of underhung and top running cranes ranging from 5-20
ton capacities, provide lifting assistance for major locomotive components
during the repair and maintenance process of the cranes.
Due to a lack of standardized inspection practices, timing and content of
inspections were inconsistent which resulted in unacceptable levels of
crane reliability and safety standards.
SOLUTION
Inspections, preventive maintenance and modernizations
Konecranes provided and continues to provide a standardized monthly
crane inspection/preventive maintenance program to ensure the equipment
operates in both a safe and reliable manner. Konecranes inspectors and
UPRR maintenance staff work in partnership to identify safety/productivity
issues and create repair plans to eliminate deficiencies in a timely manner.
In addition, modernization recommendations are presented, when
applicable, to increase the ergonomics for crane operators, speed up
processes that require the use of the cranes and enhance the level of
safety when the cranes are in use.
RESULTS
Over 60% reduction in crane repair cost
As a direct result of Konecranes inspection/preventive maintenance
partnership, the North Platte shop realized a 62% reduction in emergency
repair costs and 64% reduction in planned repair cost from 2009 to 2010.
Improved crane uptime led to total maintenance cost savings.

18. 34
A Midwest Locomotive Shop
EXTEND EQUIPMENT LIFE AND ENHANCE
SAFETY WITH EQUIPMENT INSPECTIONS
CHALLENGE In addition to displaying the rated load, ASME B30.20 requires the
Unmarked equipment fails manufacturer’s name (or contractor’s name if fabricated on-site) and lifting
to meet safety requirements device weight for items over 100 pounds be displayed on structural and
This Midwest locomotive shop helps mechanical below-the-hook lifting devices.
link production and consumption To meet these requirements and thereby improve safety, Konecranes
points in the U.S. with a network to performed an engineering study to determine the capacity of each unit and
deliver energy, food, raw materials marked each accordingly. In addition, non-destructive testing was provided
and consumer goods to support the to ensure material integrity.
nation’s growth.
RESULTS
The shop inspects, repairs and provides maintenance to locomotives 24
Regulations are met, improving safety and reducing equipment overload
hours per day, seven days a week. Services include: change-outs of power
assemblies, traction motors, alternators, turbos, engine blowers and OSHA and ASME regulations have been met due to marking each piece of
electrical equipment. On average, they complete six extensive locomotive equipment with the appropriate capacity rating, manufacturer and device
inspections per week. Their eight critical cranes provide lifting assistance weight as needed. Due to the new markings and material integrity testing,
for major locomotive components during the repair and maintenance overloading of the below-the-hook devices decreased, raising the level of
process of the locomotives. safety within the shop.
This particular shop has an abundance of below-the-hook lifting devices Of critical importance, a tailored inspection program was developed
that were manufactured either in-house or are very old. These devices did to enhance safe operation of these units for everyday use and meet
not meet OSHA and ASME requirements due to a lack of capacity markings. additional inspection guidelines called for in ASME B30.20. Along with
Due to their age, the material integrity of each unit was also in question. creating a proactive safety environment, the inspection program may
extend the life span of the equipment now that appropriate capacity loads
SOLUTION are taken into account.
Capacity levels determined with engineering study and NDT testing
Two requirements from OSHA and ASME needed to be met, OSHA
1926.251(a)(4) and ASME B30.20.
OSHA 1926.251(a)(4) stipulates that special custom design grabs,
hooks, clamps or other lifting accessories, shall be marked to indicate
the safe working loads and shall be proof-tested to 125% of their rated
load prior to use.

19. 37
An Underground Mining Equipment Manufacturer
Konecranes MTS works overtime to
finish repair weeks ahead of schedule
challenge
Critical machine tool breaks down
An underground mining equipment
manufacturer, located in the western
United States, is a worldwide
leader in high-productivity mining
equipment. Machine tools are
essential components in their
production line.
One day, a breakdown of a critical
path machine tool, a Horizontal
Boring Mill (HBM), delayed processes down the line. Every day the machine
tool was down had a major impact on parts production, which created a
company-wide problem.
The original equipment manufacturer (OEM) started emergency repair
services on the HBM, but was not able to complete them. The mining
equipment manufacturer needed a quick turnaround in order to meet their
customer’s demands for parts.
SOLUTION
Repair completed—two weeks ahead of schedule
Because of the comprehensive familiarity Konecranes Machine Tool
Service (MTS) had with this particular machine, both electrically and
mechanically, Konecranes was the ideal choice for the project. Konecranes
MTS was contacted and a qualified service engineer was dispatched
immediately to evaluate, repair and rebuild the machine. The Engineer
worked through weekends to satisfy the customer and the machine was
back into production in record time—two weeks ahead of schedule.
RESULTS
Trusted partner for the future
The underground mining equipment manufacturer has scheduled
Konecranes MTS for several modernization projects since that emergency
repair. They continue to contact Konecranes MTS as service or preventive
maintenance needs arise.

20. 38 39
A Mining Machinery Company A Mining Equipment Manufacturer
precision calibrated machine achieves Advanced Machine Modernization
highest level of accuracy Decreased Downtime and Set up time
challenge While Increasing Overall Efficiency
Struggling with tight tolerance CHALLENGE
A mining machinery company uses Aged equipment and high maintenance costs
sophisticated machine tools to A mining equipment manufacturer uses sophisticated machine tools to
manufacture and repair products manufacture products for the underground mining industry. A critical
for the mining industry. One of machine tool experienced downtime due to aged machine tool components.
their Cincinnati Gilbert Horizontal They needed a qualified machine tool service team to modernize the
Boring Mills (HBM) was struggling Giddings and Lewis Horizontal Boring Mill (G&L HBM) in order to minimize
to perform tight tolerance work. downtime and reduce maintenance expenses.
Because of Konecranes Machine
Tool Service’s (MTS) experience SOLUTION
with this equipment, they were able to use their preventive maintenance Machine redesign and rebuild
program to evaluate the situation, review findings in real time, make the Konecranes Machine Tool Service (MTS) was selected to modernize the
necessary adjustments and confirm the results. G&L HBM. The modernization project involved a complete redesign of the
spindle carrier. The aged planetary hydraulic gear box was removed and
SOLUTION replaced with a two-speed planetary gearbox system which simplified the
Assessment and re-calibration headstock with fewer wear parts. The new design eliminated the need to
For the Cincinnati Gilbert HBM, Konecranes MTS performed a complete replace the hydraulic valves and gears at a high price and a long lead time.
assessment of the machine’s geometrical condition. Then, MTS service
engineers used Mahr Federal electronic levels to precision level the A digital spindle drive system was integrated with the latest Fanuc CNC
machine to exceed the original manufacturer’s specifications for pitch control system. The new CNC control system gave the facility the flexibility
and roll. to control the spindle speeds between minimum and maximum available
RPM when adjusting the stock removal. Konecranes developed a customized
Konecranes MTS state of the art Renishaw ML10 interferometer laser control pendant equipped with an LCD screen which enhanced safety by
system was used to calibrate the positioning accuracy of the machine. allowing the operator to have closer access to the parts they set up.
After the machine had been precision leveled and laser calibrated and a
Renishaw ballbar had been run to confirm the results, the mining machinery RESULTS
company was able to confirm with their coordinate measuring machine Reduced cost and downtime, increased throughput
substantial improvements in their product’s quality. The Giddings and Lewis HBM modernization decreased downtime while
increasing throughput and efficiency. Maintenance costs were greatly
RESULTS reduced. Konecranes will continue to perform preventive maintenance,
Highest ever level of accuracy, beyond original specifications calibration and service support.
After Konecranes MTS optimized the Cincinnati Gilbert HBM, it performed
at the highest level of accuracy ever achieved in its lifetime. The improved
machine repeatability and accuracy reduced set up time for parts by
minimizing the necessary adjustments to accommodate the machine’s
geometry issues.

21. 40
A Leading Mining Manufacturer
OPERATOR TRAINING IMPROVES
SAFETY, PREVENTS EQUIPMENT
DAMAGE AT a GYPSUM QUARRy
challenge RESULTS
Frequent breakdowns from Operator training + new cranes = long term relationship
suspected improper use The success of the operator training program in reducing equipment
A leading manufacturer of gypsum damage led to Konecranes having contracts for virtually all of the
wallboard operates a quarry in North customer’s crane maintenance needs. The mine also began purchasing
America. The quarry processes up new-generation Konecranes CXT cranes with variable speed bridge and
to 20,000 tons of rock per day, trolley motions and built-in load limiting devices to replace older cranes.
which is extremely hard on material The numerous safety and low-maintenance features of the CXT were an
handling equipment. excellent fit for the mine, where reducing maintenance expenses is a
prime objective.
The mine uses a fleet of 10-ton
overhead cranes to maintain large According to the mine’s maintenance planner, the training program has
transfer trucks and other mining made all the difference. Now, every crane operator must complete the
equipment. They had frequent crane operator safety course in order to operate a crane at the facility.
crane breakdowns and experienced Konecranes has become a valued contributor toward improving the mine’s
problems with ropes being pulled off the drums when the loads were too safety and production.
heavy for the cranes, allegedly from improper operator use. Only a few
of their cranes had load limiters installed. Purchasing higher-capacity
equipment was not an economical option.
SOLUTION
RFQ for maintenance led to operator training as the fix
The mine began looking at outsourcing crane inspections and
maintenance. An analysis of contractors based on a formula comparing
rates, documentation, competency of technicians and other factors
revealed Konecranes as the leading supplier. The relationship began with
Konecranes providing inspections only, with the mine performing repairs and
maintenance on the items Konecranes identified.
After seeing the recurring damage caused by operators attempting to lift
loads too heavy for the equipment, Konecranes recommended that they
implement a mandatory crane operator safety training program. Going back
to the equipment manuals, Konecranes showed operators how to break
down the trucks into elements weighing 10 tons or less­­ sections that the
,
equipment could handle. The safety training program showed the operators
the basic methods of calculating the weight of identified sections.

22. 43
Elevating Boats, LLC, Braithwaite, La.
Advanced machine restoration enhances
safety and improves ease of use
challenge Before
Critical machine damaged
by Hurricane Katrina
Elevating Boats (EBI), LLC in Braithwaite,
La. uses machine tools to manufacture
offshore lift boats, pedestal cranes,
hydraulic cylinders and many other
mechanical and hydraulic components
for the global boating industry. Machine
tools are essential in manufacturing their After
products and components.
In 2005, a highly-specialized vertical boring
mill (VBM) was damaged in Hurricane
Katrina. As a core machine to the EBI
product line, the loss of this machine
reduced their capacity to meet the demands
of their customers.
Three proposals were generated for this project. Konecranes MTS was
chosen based on having the best value proposition because Konecranes
employed the most talented technological team, with experts in every
area required for the project. The plant manager at EBI had worked with
other retrofitters in the past, but he did not believe that they had enough
mechanical expertise to retrofit this machine.
SOLUTION
Konecranes MTS retrofits machine, adding safety features
Konecranes MTS performed a complete retrofit of the machine. An
advanced feature was added which allowed for a more dependable location
of the movable rail through a process called synchronous axis control. This
improvement enhanced safety and made the machine easier to operate. An
additional enclosure was added for safety.
RESULTS
The machine is completely restored, with added features
The machine was restored to its original geometry and positioning
specifications. The updates allowed the operator more flexibility for
assembling complex parts. Because of the project success, Konecranes
MTS is the favored supplier to rebuild and retrofit another machine.

23. 44
National Oilwell Varco, Houston, Texas
Enhancing safety with crane
operator training course
challenge The instructors put their knowledge in layman’s terms and performed
Crane operators hands-on training to show employees proper rigging techniques, load
need training support ratings, and inspections on their own equipment.
When industry leader National “Of all the training programs I reviewed, the Konecranes Institute
Oilwell Varco (NOV) in Houston, presented the best course outline, offering the most comprehensive
Texas, began searching for a strong coverage within a good time frame,” says Christy Exley, Health, Safety,
crane operator training program Environment (HSE) Manager at NOV in Houston. “The Konecranes Institute
that could enhance safety and offers a true Train-the-Trainer class,” says Exley. “One of its greatest
increase awareness at multiple benefits is that the instructor teaches not only overhead crane operation,
NOV facilities, the company but the basics of becoming an effective instructor.”
singled out the Overhead Crane
Train-the-Trainer course from the RESULTS
Konecranes Training Institute. The Training considered number one accomplishment of the year
program provides a cost-effective Vernon Miller, corporate HSE regional manager for NOV, says that NOV
approach to training personnel, employees received the knowledge to move forward safely. “Looking back
presenting future trainers with on the accomplishments my group has made this past year, the Institute
basic to complex information, and training is the number-one selected achievement that was accomplished,”
equipping them with instructional says Miller.
skills to train employees internally
throughout the company.
Instructors of the Konecranes Training Institute have extensive “Even employees with more than 15 years
overhead lifting experience, teaching first-hand knowledge about experience said they came away from the
proper crane operation, maintenance, and best practices to improve course having learned something new.”
safety and compliance, productivity, and lifecycle value of equipment.
Christy Exley, Health, Safety,
The Institute has trained operators in industries such as steel, Environment (HSE) Manager, National Oilwell Varco
utilities, chemical, automotive, foundry, nuclear power, mining,
aerospace, paper and waste-to-energy.
SOLUTION
Konecranes provides comprehensive, hands-on training
In the fall of 2008, several NOV facilities throughout the country
received on-site Train-the-Trainer instruction from the Konecranes
Institute. NOV crane operators with varying levels of experience,
from as few as two years to as many as 25, participated in the
training program.

24. 46
A Southern Manufacturing Company
equipment breakdowns Decreased
by 60% with proper maintenance
CHALLENGE
Four to six breakdowns per week
A Southern manufacturing company
develops specialized equipment
for the oil and gas industry. Each
of their 16 25-ton overhead cranes
is essential to meeting the high
production needs of the facility. The
company that had been servicing
their cranes tended to focus on
problems after they occurred, rather
than working to prevent them. As a result, the cranes had an average
of four to six breakdowns per week. When the Southern manufacturing
company noticed that their cranes were experiencing the same type of
breakdown repeatedly, they began to look for a new company to service
and maintain their equipment.
SOLUTION
MAINMAN®inspections and preventive maintenance
The Southern manufacturing company contacted Konecranes after one
of their critical cranes experienced a breakdown during off-peak hours
over a weekend. A Konecranes emergency response team was dispatched
immediately upon being contacted. After successfully completing the
repair, Konecranes proposed an annual inspection contract for each of
their cranes using the MAINMAN® inspection program. MAINMAN®is
an active preventive maintenance program that uses a multi-point
visual inspection to capture data on the condition of over 225 crane
components. The data is then used to create a customized plan for
scheduled maintenance and repairs. Konecranes currently conducts
annual MAINMAN® inspections at the facility and completes scheduled
preventive maintenance repairs as needed.
RESULTS
Breakdowns decreased by 60%, overall decreased costs
Since Konecranes began conducting preventive and planned
maintenance two years ago, equipment breakdowns at the facility have
decreased by over 60%. As a direct result of the MAINMAN® inspection
program, maintenance spending and downtime expenses have been
dramatically reduced.

25. 48
BC Hydro, Mica Generating Station,
British Columbia
TECHNOLOGY DEVELOPED
FOR NUCLEAR INDUSTRY
EXPEDITES UNDERGROUND
CRANE INSTALLATION
challenge the cavern without removing ceiling
Specialized installation needed supports or, most importantly,
for underground facility disrupting power generation.
When BC Hydro built their Mica generating station This patent-pending jacking tower,
on the Columbia River in 1977, it was designed the only one of its kind in the world,
to hold six generating units. But only four were was delivered by tractor-trailers
initially completed, pending a need for more power and assembled inside the cavern
in the region. to the required height. The jacking
In 2011, the Mica Units 5 and 6 Project was tower rests on a base that allows
launched to install the two remaining generating for even load distribution, one large
units, adding another 1,000 MW of power advantage over mobile cranes, whose tires have a very small footprint.
generating capacity. Another advantage is a jib arm that can be used to raise and lower
To service them, BC Hydro bought two new turbine smaller loads. The jacking tower not only has the ability to remove all
hall cranes from Konecranes, designed to work in components from under the crane rather than above, but it also installs
tandem to provide synchronized lifts. At 575 tons the cranes from below.
each, these massive double girder cranes were
RESULTS
the largest ever delivered by Konecranes in North
Equipment installed with minimal production interruption
America to date.
According to Owen Williams, BC Hydro’s project manager, Konecranes
Because the entire Mica facility is carved into jacking tower technology and its ability to install from below was a real
a mountain, the cranes must operate inside an advantage in the underground location.
underground chamber accessed by a 400-foot
“Konecranes had an elegant way of replacing the existing cranes with new
tunnel. Normal installation inside the underground
ones which allowed us to install new cranes while having a limited impact
facility using mobile cranes was not an option, as
on the operating generating station,” he said.
they would not fit in the limited headroom without
removing ceiling supports.
“Our generating station continued to provide
SOLUTION approximately 15% of BC Hydro’s total power
One-of-a-kind jacking tower generation output during this project.”
installs equipment from below
Working with Konecranes Nuclear Equipment & Owen Williams, Project Manager, BC Hydro
Services, Konecranes utilized a state-of- the-art
technology developed in 2010 for the nuclear
industry to make the challenging install inside

26. 50
R.E. Ginna Nuclear Power Plant, Ontario, N.Y.
Specialized Crane Enhances Safety
Through Advanced Engineering
challenge This was accomplished by designing a
High-capacity crane needed hybrid single failure proof crane that was
to handle spent fuel actually installed outside of the crane
When R.E. Ginna Nuclear Power operating area, but that is able to access
Plant needed a specialized high the crane operating area by telescoping
capacity crane to be able to off-load into the building. This is no small feat
spent fuel from their fuel pool to considering the crane is rated at 125-
dry cask storage, they trusted the tons, is single failure proof and that it
expertise of Konecranes. reaches into the building to pick up spent
nuclear fuel.
“We needed to find a partner that
could provide us with a significant RESULTS
capacity crane and crane configuration dedicated design. One of the Konecranes continues to provide
challenges was the fleet cask size – a 125-ton cask – that dictated crane service and support
crane configuration,” says Mark Fitzsimmons, Principal Engineer, Nuclear “The crane was installed and delivered on
Engineering Services, from Constellation Energy Nuclear Group. time, but there were some original materials
that weren’t as compatible as we would
SOLUTION have liked. But Konecranes supported us
Crane developed to meet space, capacity, through the problems, and we ran our first
safety and regulatory requirements campaign without a hitch.”
After a competitive bid process, Konecranes was selected as a turnkey
supplier of a complex single failure proof crane. Konecranes is now under contract to
provide maintenance service for the crane,
During the process of assessing the project, a new challenge was thereby ensuring that it is properly cared for
determined: the building structure surrounding the fuel pool was not originally during its lifetime and that it will perform
designed to support the weight of a fully loaded 125-ton single failure proof the key tasks that are necessary to load
crane that was required to move and load the spent fuel for dry cask storage. and handle spent nuclear fuel.
Konecranes and Ginna worked closely together during the entire project to
make sure the solution would meet the demanding requirements. According to Mark, business is growing and they will need high performing
cranes as well as support for older cranes on a fleet-wide scale. This could
Handling spent nuclear fuel is a highly specialized task and requires lead to opportunities for more successful joint projects in the future.
compliance with strict and comprehensive regulatory requirements of the
U.S. Nuclear Regulatory Commission. Konecranes knew that it had the
technical knowledge to solve the problem, along with the ability to comply “Konecranes came up with a new solution based on our
with the stringent requirements of NUREG-0554 and ASME NOG-1 single current situation. It was an innovated idea, and they
failure proof crane design criteria. presented a model that showed the outcome.”
Mark Fitzsimmons, Nuclear Engineering Services, Principal Engineer

28. 54
Liberty Paper, Inc., Becker, Minn.
Crane Modernization goes over and
above to win long-term relationship
challenge
Determine the current condition and
remaining life of a dry end crane
Liberty Paper, Inc. (LPI), part of the
Liberty Diversified International
family, is a state-of-the-art paper
mill, located in Becker, Minn. that
recycles old corrugated containers
into new paper for packaging. The
mill manufacturers recycled paper
from more than 240,000 tons of
corrugated containers each year.
In June 2009, the company turned to Konecranes to complete an end-of-life
study on their dry end crane, used primarily in the manufacturing process.
The crane had originally been purchased from Konecranes in 1994.
SOLUTION
Konecranes end-of-life study used to scope a modernization A Konecranes sales representative explains, “This gives them a lot of
After the end-of-life study was complete, LPI received three quotes to flexibility in the future.”
upgrade the equipment. Konecranes provided the best added value Sixty cycles after the modernization was completed, the hoists were tested
proposition to LPI, therefore, Konecranes was awarded the job in April for synchronization, which is crucial in the paper process. These critical
2010. The primary factor was because of the end-of-life study. Konecranes hoists ran in tandem within one inch of each other
offered an immediate solution that allowed for future expansion plans.
Since the installation, Liberty Papers has signed a service contract with
In August 2010, Konecranes installed the modernization to the dry end Konecranes. The service contact includes monthly preventive maintenance.
crane. Konecranes worked around the clock, beginning Monday at 6 a.m.
The job was completed by Friday at noon – 24 hours ahead of the deadline. Currently, Konecranes and Liberty Paper are discussing plans to perform
The installation came in on budget and required no downtime from LPI. these same modernizations to an LPI wet-end crane.
RESULTS
Modernization completed on time and on budget, cranes
equipped with excess capacity for future expansion
Both hoists were modernized to 30-ton. The hoists were then de-rated
to 20-ton cranes, allowing them ample expansion room for future plans.