The practice of using simulators for crane training originated in the early 2000s, when simulation technology was first adapted for training purposes. That initial step was a breakthrough in operator training.
Suddenly, there was an option that made training faster, more affordable, and—most importantly—safer than any other approach to date. Early adopters also saw significant improvements in overall productivity, emissions reductions, and recruitment efforts.
Since then, advancements in computer graphics, processing power, and display technology have only enhanced the capabilities of simulation training for crane operators. Today, crane simulators are used to recruit, train, assess, and upskill operators, while also preparing these workers for certification exams, specific lifts, and meeting internal qualification requirements.
To continue advancing crane simulation training, CM Labs recently introduced a new generation of technology. Known as Intellia, this Intelligent Training System integrates the benefits of simulation training with additional instructor tools, advanced reporting features, and the ability to scale up training efforts while offering increasingly personalized instruction.
So, what are crane simulators? What’s the difference between a simulator and a simulation? Why have crane simulators surged in popularity in the last decade?
Here’s a closer look at why this approach is so popular and effective.
When you sit down at a simulator and power it up, you use it to try a variety of different exercises on a variety of different cranes and other heavy equipment. Within the simulated environment, you move materials, navigate obstacle courses, and even learn how to handle environmental challenges like windy conditions. The crane simulations recreate the real world in stunning detail, immersing you in the sounds, sights, and sensations of a real work environment. So, how does all of this technology work together to make it all happen?
Often, the terms crane simulators and crane simulation are used interchangeably, but there is a difference between the two. Here’s a quick overview of what these terms technically mean:
What is a crane simulator? Put simply, a crane simulator is a sophisticated piece of hardware powered by simulations that can range in quality from hyper-detailed to game-based. Crane simulators typically feature the following:
Visual displays: A simulator’s screens provide the visual immersion necessary for the operator to navigate the simulation. Display setups vary from single- to multi-screen configurations, such as 3-screen, 5-screen, and beyond. Users can customize the display number and arrangement to meet specific requirements.
Controls: The controls operators use to maneuver through the simulation can range in quality from gaming controls to industry-grade controls. Some simulators include hot-swappable controls that can be easily removed and added. This offers the flexibility of using one simulator to train operators on many different types of cranes.
Operator touchscreen: A touchscreen that provides added control options, and also functions as the Load Moment Indicator (LMI).
Seat: Sometimes the seat of a simulator is mounted on a motion platform—which recreates the physical sensations of operating a crane.
Crane simulations are the brain behind the simulator, creating the virtual environment and scenarios used for training purposes. Crane simulations include the following:
Virtual Worksite: An immersive representation of construction sites, ports, or other operational environments where cranes are typically found. These representations will include photorealistic visualizations, sounds, lighting, and environmental conditions.
Machine Behavior: Advanced algorithms simulating the behavior of the crane and its interactions with the environment. This includes many important aspects of crane operation, such as:
Load chart
LMI (simulated controls panel)
Pendulum
Cable reeving
Cable properties and slackness
Loads and rigging
Lifting apparatus (including different spreader bars and types of hooks)
Wind effects
Collisions
Training Exercises: Pre-programmed exercises and scenarios that range from basic operations to complex tasks, designed to train operators on various skills. These exercises can include learning the crane’s controls, how to set up the crane, how to secure the crane at the end of operation, how to control the pendulum, how to read the LMI and have an understanding of the load chart of the crane, how to lift different types of loads with or without lifting apparatus, how to interact with a signalperson, how to perform complex operations such as a dual lift, and safety-related topics such as avoiding situations that place the load over a person. Some simulations will even include test courses and exercises designed for certification preparation.
Performance Analytics: Data on the trainee’s performance that can be used for further analysis, and to identify strengths and weaknesses. These metrics can include productivity-related metrics such as how long it took for the operator to complete a task, as well as other important metrics such as how many times the operator had an uncontrolled pendulum, how often they had a collision, and how many safety violations they had.
Preparation for the Unexpected: Some simulations have the ability to introduce unexpected elements such as machine malfunctions and environmental distractions into exercises at any time. This allows an operator to experience situations such as a rigging line break or a cell phone ringing at an unexpected time within an exercise, and learn how to safely navigate these challenges.
Many people mistakenly think that a simulation’s success will only depend on the quality of either its hardware or the simulation technology that powers it. While both are very important, how they interact with each other has a significant impact on the quality and realism of the crane training provided. The motion platform’s response to actions within the simulation or the resistance of the controls, for example, teaches the physical cues operators need to watch for on the job. So too does the load moment indicator’s ability to control some aspects of the machine from the touchscreen. It is this connection between hardware and the technology that powers it—between simulator and simulation—that builds muscle memory and ultimately allows operators to develop their skills.
Simulators and their simulations can replicate various types of cranes, each catering to specific training needs and industry applications.
Often, the same piece of hardware can be used to run multiple training packs. This means that one simulator can be used to train operators for tower crane operation, mobile crane operation, and even earthmoving equipment operation, for example. All a trainer would need to do is swap out the controls for one type of equipment and add in the controls for the other.
Some of the most common types of crane simulations include:
Flat-top tower cranes are commonly used in construction for lifting heavy materials to great heights. Flat-top tower crane training simulators and their simulations replicate the high-rise environment and operational challenges associated with these cranes. Trainees can practice operating the crane’s jib, trolley, and hoist mechanisms, as well as manage critical elements of tower crane safety, including managing pendulum loads and complex rigging setups typical in construction sites.
Mobile crane simulators, like many other crane simulators, provide detailed metrics on things like rough load handling, time spent in pendulum, and collisions. These metrics provide insights on aspects of operation essential to mobile crane safety training, helping to bring data and objectivity to operator training and assessment. Operators can use these simulators to learn how to effectively maneuver the crane, stabilize it, and handle loads safely in diverse environments.
Because luffing tower cranes offer good maneuverability in tight urban environments, luffing tower crane simulators will often focus on preparing operators for work in these types of environments through exercises in tight spaces. Some simulations even provide certification prep, with dedicated exercises that help trainees practice for the CPCS (Construction Plant Competence Scheme for cranes) or CCO (formerly the National Commission for the Certification of Crane Operators) exams.
Crawler cranes are heavy-duty machines often used in large-scale construction projects and heavy lifting tasks. For this reason, crawler crane operator training simulators allow operators to practice lifting, rotating, and moving loads while managing the stability and balance of the crane. Some crawler crane simulations may even include lift planning for exercises, as well as preparation for the CCO (formerly the National Commission for the Certification of Crane Operators) or CPCS (Construction Plant Competence Scheme for Cranes) exams.
Because boom trucks are often used for utilities work, they are an especially good candidate for simulation training, allowing trainees to practice these high-risk situations in complete safety.
Boom truck simulations offer detailed metrics on performance, including safety violations for enhanced safety training. In addition, some may also provide CCO (formerly the National Commission for the Certification of Crane Operators) certification exam preparation.
Mobile harbor cranes are crucial for port operations, handling a wide variety of cargo types. Mobile harbor crane simulators replicate the operation of these cranes, enabling operators to practice loading and unloading containers, bulk materials, and break bulk with precision. These simulations also help operators develop the skills needed to manage the unique challenges of port environments, such as space constraints and variable weather conditions.
Rubber-tired gantry cranes are the workhorses of yard operations and a crucial part of port operations. Rubber-tired gantry crane simulators allow operators to practice stacking containers as well as working with overheight, open-top, break bulk, and liquid containers. Some simulations will even replicate twistlock behavior, allowing operators to feel the realistic experience of locking the spreader onto the container.
As fixed cranes on ships, ship pedestal cranes are notoriously hard to train on, given that they can only be operated when a ship is in port. Because ship pedestal crane simulators allow operators to practice without the real equipment, they are an especially popular choice among ports looking to boost productivity. Simulation training offers scenarios that mimic real-life conditions, allowing operators to practice precise movements and cargo handling techniques.
As the most common piece of heavy equipment used by ports, ship-to-shore cranes are essential for transferring containers between ships and the dock. Ship-to-shore crane simulators provide a realistic training environment where operators can practice the intricate operations of these massive cranes. Simulated exercises often focus on precision, speed, and safety, preparing operators for the demands of port operations. These simulations are excellent for enhancing overall port productivity, and are the most common type of crane simulation training found in modern ports.
Crane simulators and their simulations are versatile tools with a wide range of applications. Their flexibility makes them suitable for various training and assessment needs, including the following:
- Garnering interest at career fairs and other recruitment events
- Testing experienced operators during job applications to ensure they have the skills they claim to
- Testing operators before they work in a high-risk setting to help prevent safety incidents and demonstrate due diligence
- Assessing the skills of professionals working in other capacities within an organization, to see if they have the natural aptitude needed to become an operator
- Training operators for specific lifts
- Upskilling and cross-skilling during downtime
- Certification preparation
In fact, some organizations even keep their simulators housed in trailers to bring them on the road to act as a mobile billboard. There is no shortage of ways organizations can and do use crane simulators.
Incorporating simulation into crane operator training programs provides significant benefits. Organizations that use crane simulator training often benefit from:
- Improved safety
- Reduced training times
- Better corrective training
- Improved productivity
- Reduced emissions
- Improved operator retention
- Cost reductions
These benefits are due to the safe, controlled environment that crane simulation provides, as well as its ability to decouple training from equipment availability. As a result, many crane simulators quickly pay for themselves in cost savings within a short time after deployment.
Today, contractors, training schools, construction CTE programs, trade schools, ports, and labor organizations use crane simulation in their training programs and operations.
It’s not a surprising development. Crane simulation training offers numerous benefits. Its ability to enhance safety, improve productivity, reduce emissions, speed up training times, boost operator retention, and reduce costs makes it a strategic asset.
Want to learn more about how simulation can benefit your organization? Check out our ebook on Measuring the ROI in Simulation-Based Training!
