How One High-Capacity Crane Replaced Two to Keep Steel Erection on Schedule

Steel erection projects demand precise coordination between lifting equipment, crew scheduling, and structural sequencing. When a project involves 1,300 separate picks within an eight-week window, the choice of crane configuration can determine whether the job finishes on time or falls behind. One Texas-based contractor faced exactly this challenge on a 290,000-square-foot building expansion and discovered that replacing two smaller cranes with a single higher-capacity unit was the key to staying ahead of schedule. This case study explores how the decision to use one crane instead of two transformed the project’s trajectory and offers insights for construction professionals managing similar steel erection work. Understanding these principles is essential at every stage of a project. For a broader overview of how projects move from concept to completion, refer to Key Facts About Construction Project Life Cycle Phases.

The Steel Erection Challenge: Project Scope and Original Lifting Plan

Big B Crane and its sister company Basden Steel Corporation, both based in Burleson, Texas, partnered with Deem Structural Services of Longview, Texas, to deliver steel erection services for a 290,000-square-foot, 2,100-ton building expansion project. The client was a leading global aerospace company, and the schedule was exceptionally tight. The contract began in May 2015 and closed just five months later, with the full building project expected to be completed by summer 2016.

Project Parameters

The steel erection scope for this two-story structure included demanding targets that tested the capabilities of any crane fleet:

• 1,300 total picks within an eight-week lifting schedule
• 120 picks involving objects weighing 11,000 pounds or more
• Heaviest single piece at 12,500 pounds
• Goal of 50 pieces lifted per day to meet the schedule
• Strict coordination required between steel delivery, fabrication, and erection crews

The Original Two-Crane Strategy

The original lifting plan called for two 150-ton capacity class cranes working in tandem. Each crane would handle lighter pieces independently, but for the heavy structural components weighing over 11,000 pounds, both cranes would combine in a tandem lift configuration. While this approach appeared workable on paper, it introduced significant operational inefficiencies that threatened the already tight schedule.

Ben McGregor, Vice President of Basden Steel’s Oklahoma division, described the core problem: “You have to coordinate the swing radius when working with two cranes, so there is a lot of crane downtime. If a single crane can be used, this reduces the time for many of the picks, and it increases lifting safety.” The tandem lift approach meant that every heavy pick required precise choreography between two crane operators, limiting speed and introducing additional points of potential delay.

Why a Single High-Capacity Crane Outperformed Two Smaller Cranes

Daniel Basden, President of Big B Crane, recognized that changing market conditions in Texas and Oklahoma were driving the need for higher-capacity lifting equipment. Concrete precast panels were getting bigger and heavier, steel members were getting longer, and the company’s existing fleet of two 250-ton class crawler cranes could not deliver the capacity needed to eliminate tandem lifts on projects like this building expansion.

The Capacity Gap Problem

The fundamental issue was straightforward: using two 150-ton cranes for tandem lifts of heavy pieces introduced coordination overhead and slowed the work pace. A single crane with sufficient capacity could handle the same loads without the need for dual-operator synchronization. The question was what size crane would fill the gap.

The initial consideration was to jump directly to a 300-ton class crane. However, this option came with a substantial drawback. As Daniel Basden explained, “The jump to the 300-ton capacity comes with a significant additional capital investment.” Beyond the purchase price, a 300-ton crane also introduced higher transportation costs, since many 300-ton crane carriers ship in two pieces, requiring an additional truck, driver, and extra setup time.

The Value of a Mid-Size Solution

When Big B Crane representatives met with Terex Cranes distributor Scott-Macon Equipment of Houston and Terex representatives, the conversation turned to a recently introduced model: the Terex HC 285 crawler crane, rated at 285 tons capacity. This crane occupied a sweet spot in the market that the contractor had not previously considered.

Jim Strobush, Senior Product Manager for Crawler Cranes at Terex Cranes North America, described the HC 285 as “a good in-between crane that gives customers virtually the capacity of a 300-ton class crane but at a price similar to that of a smaller crawler crane, so a company can receive a high return on investment.” For Big B Crane, this value proposition was exactly what the project needed.

For context on how equipment selection fits into the broader scheduling process, see Construction Project Scheduling Methods Tools and Best Practices.

Terex HC 285: Technical Specifications and Capabilities

The Terex HC 285 lattice boom crawler crane brought a combination of reach, capacity, and transportability that made it the ideal choice for this project. Understanding the technical specifications helps explain why one crane could effectively do the work of two.

Key Specifications

Transport and Setup Advantages

One of the most practical advantages of the HC 285 was its transportability. The base crane carrier measures less than 10.5 feet wide by 12 feet high, enabling transport on a standard low-boy trailer without special permits for most routes. This stood in contrast to many 300-ton class cranes whose carriers require splitting into two pieces for transport.

The HC 285 was shipped directly from the Terex Oklahoma City facility, which was located less than 10 miles from the project site. This proximity meant the crane arrived quickly and was assembled and put to work with minimal delay. Big B Crane fast-tracked the order through Scott-Macon Equipment specifically to meet the building expansion schedule.

Safety Enhancements

Safety was a high priority on this project, and the HC 285 included several noteworthy safety features. A new tram fall protection system equipped the full length of the boom with 20-inch-wide, heavy-duty, non-slip aluminum walkways. A track-guided travel tram offered single-point harness hookup, giving workers full-length access to the boom during assembly and disassembly without needing to reposition their safety line. These features reduced the risk of falls during crane setup and teardown, a phase where many lifting-related injuries occur.

To understand how steel erection methods integrate with broader structural engineering principles, see Steel Bridge Design and Construction Fabrication Erection Methods.

Results and Lessons for Future Steel Erection Projects

Execution: The Lift Plan in Action

The lift plan for Basden Steel involved positioning the HC 285 crane at the center of the building and slowly moving it down the structure’s length. From this central position, the crane lifted steel beams, joists, decking, and staircases to both the left and right sides. This approach minimized the number of crane repositioning moves and maximized productive lifting time.

Full upper and car body counterweight was used throughout the project, and the crane was equipped with 180 feet of main boom and the full 100-foot 16 HL jib. The crew averaged working at a 180-foot radius for the lifts.

Schedule Performance

The schedule results demonstrated the impact of the equipment decision:

1. The project started three days behind schedule due to initial setup and coordination
2. Despite the late start, the crew aimed for 50 pieces lifted per day
3. Three weeks into the lifting phase, the team was 164 pieces or three days ahead of schedule
4. The last piece of steel was hung approximately one week ahead of the original schedule
5. The total project duration was about seven weeks instead of the planned eight

In total, Big B Crane, Basden Steel, and Deem Structural lifted and placed 2,100 tons of steel in about seven weeks using the single HC 285 crane. As Daniel Basden summarized, “The HC 285 has a phenomenal lift chart. There is no way we could have finished this project as efficiently as we did without this crane being on site.”

Cost and Logistics Benefits

Beyond the schedule gains, using a single crane instead of two delivered measurable cost and logistics advantages:

• Eliminated the need for a second crane operator and rigging crew
• Removed the coordination overhead of managing two swing radii
• Saved the demobilization cost of a second crane at project completion
• Reduced the total number of truckloads needed to transport equipment to and from the site
• Simplified the daily lift planning process since the single crane could handle all picks without needing tandem configurations

Key Takeaways for Project Managers

The HC 285 success story offers several lessons applicable to steel erection and general construction projects. First, carefully evaluate the middle range of equipment options rather than defaulting to either the lowest-cost or highest-capacity solution. The HC 285 provided 300-ton-class performance at a price point closer to smaller crawler cranes, representing an optimal value for projects with demanding lift requirements. Second, consider the total cost of crane operations, not just the rental or purchase price. Transportation, setup, demobilization, and crew coordination costs can significantly impact the overall project budget. Third, safety enhancements in modern lifting equipment can provide tangible benefits for crew productivity and risk reduction. Features like the tram fall protection system on the HC 285 allow crews to work faster because they can access the boom more safely during assembly and disassembly.

For additional guidance on managing construction schedules effectively, see How to Build and Manage a Construction Project.

The decision to bring in a single 285-ton Terex HC 285 crane instead of using two 150-ton cranes allowed Big B Crane to complete 1,300 picks and place 2,100 tons of steel approximately one week ahead of schedule. The project demonstrates that sometimes the best solution is not adding more equipment but selecting the right single piece of equipment for the job. As the construction industry continues to see larger precast panels, longer steel members, and tighter schedules, the ability to match crane capacity to project demands will remain a critical skill for successful steel erection management.