October 11, 1996

Intelligent Systems Division • National Institute of Standards and Technology • Gaithersburg MD

Prepared For:

Lynn Torres

Marine Corps Program Manager

Naval Facilities Engineering Service Center

CO,CDNSWC

Code 102

Bethesda, Maryland 20084-5000

Tasked By:

Marine Corps Systems Command

(MARCORSYSCOM)

Amphibious Warfare Technology Directorate

(Code AW)

Submitted By:

Dr. James S. Albus

Intelligent Systems Division

National Institute of Standards and Technology

Gaithersburg, Maryland 20899

Phase II Final Report:

ATEC Project

Air Transportable Expeditionary Crane

The National Insitute of Standards and Technology (NIST) does not endorse the products mentioned in this paper. These products are used 

for illustration purposes only and are not mentioned because they are better than another similar product.
Final Report: Air Transportable Expeditionary Crane Project

Intelligent Systems Division

TABLE OF CONTENTS

ADMINISTRATIVE INFORMATION .................................1

CONTRACT SPECIFICATIONS ..........................................3

ATEC DESIGN CONFIGURATIONS ..................................5

Container Mobilizer ....................................................... 5

Concept and Capabilities ..........................................................5

Packaging/Deployment Sequence ............................................8

Specifications .........................................................................13

Structure ............................................................................................13

Vehicles ..............................................................................................13

Winches/Actuators .............................................................................15

Power System ....................................................................................16

Spreader Bar ......................................................................................16

Cantilevered Material Handler ..................................... 19

Concept and Capabilities ........................................................19

Packaging/Deployment Sequence ..........................................22

Specifications .........................................................................25

Structure ............................................................................................25

Winches .............................................................................................25

Cabling ..............................................................................................25

Airstrip Fabrication ...................................................... 26

Airstrip Assembly Assumptions ........................................................28

Assembly Sequence and Timing .......................................................29

Utilities ......................................................................... 31

Spreader Bars .........................................................................31
Table of Contents

Digging Tools .........................................................................31

Other Tools .............................................................................32

Model Photos ................................................................34

DETAILED SPECIFICATIONS ..........................................56

Weight Analysis ............................................................57

Cost and Fabrication Time ............................................57

Industry Contacts ..........................................................58

RECOMMENDATIONS ......................................................60

FY97 Proposal ..................................................................61

FY98 Proposal ..................................................................62

APPENDIX I ........................................................................63

Phase I Report ...............................................................63

APPENDIX II .......................................................................64
Final Report: Air Transportable Expeditionary Crane Project

Intelligent Systems Division 1 of 65

ADMINISTRATIVE INFORMATION

Project Title

Air Transportable Expeditionary Crane Project

[References to this report should be made to MIPR #M9545095MPR5 

prepared on March 1, 1995]

Start / End Dates

March 1, 1995 / September 30, 1995

Resource Budget

$40K for FY95

Responsible Person / Organization

Shujie Chang, P.E.

Marine Corps Program Manager

Naval Facilities Engineering Service Center

CO,CDNSWC - Code 102

Bethesda, Maryland 20084-5000

Cooperating Organization

Marine Corps Systems Command

(MARCORSYSCOM)

Amphibious Warfare Technology Directorate

(Code AW)
Performing Organization

2 of 65 Administrative Information

Performing Organization

National Institute of Standards and Technology

Intelligent Systems Division

Building 220 Office B124

Gaithersburg, MD 20899

Point of Contact

Mr. Roger Bostelman Phone: 301-975-3426

Email: roger.bostelman@nist.gov

Principal Investigators

Dr. James Albus Phone: 301-975-3418

Email: james.albus@nist.gov

Mr. Roger Bostelman Phone: 301-975-3426

Email: roger.bostelman@nist.gov

Mr. Adam Jacoff Phone: 301-975-4235

Email: adam.jacoff@nist.gov

Associate Investigators

Ms. Kimberly Anderson

Mr. Charles Giauque

Mr. Brian Weiss

Key Words

Cranes, ISO Container Handling, Heavy Cargo Transport, All Terrain 

Vehicles, Airstrip Construction, Drilling, Digging, Robotics, Sensory 

Interactive Machines
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Intelligent Systems Division 3 of 65

CONTRACT SPECIFICATIONS

The concept of an Air-Transportable Expeditionary Crane (ATEC) must 

satisfy a few important mission requirements. That is, it must be transported via helicopter to an unimproved expeditionary site. It must be 

deployed quickly with a minimum of personnel. It must be able to 

acquire and mobilize 23 t* (25 ton) ISO containers across rough terrain. It 

should be able to stack containers two high. And lastly, it should perform 

a number of tasks associated with constructing a landing strip for cargo 

aircraft in an expeditionary environment. In order to accomplish these 

rigorous goals, a successful ATEC design must balance structural ruggedness against weight, overall size against transportability and cargo stability against dexterity. 

The ATEC - Container Mobilizer must be extremely lightweight compared to conventional container handlers. The structure must be designed 

to operate without using heavy counterweights as ballast. It must also be 

flexible enough to be packaged efficiently in an 2.5 m x 2.5 m x 6 m (8 ft 

x 8 ft x 20 ft) ISO container for quick and easy deployment in the field. 

Yet the total airlifted package, crane and container together, cannot weigh 

more than 14.5 t (16 tons). For the ATEC - Container Mobilizer to satisfy 

all these constraints, an innovative crane has been developed based on 

existing technologies but with eye toward future technological improvements.

Therefore, the FY95 research objective was to design and evaluate the 

technical feasibility of a heavy lift crane with the following design criteria: 

• Lightweight enough to be helicopter transportable.

• Compact enough to be packaged in standard 2.5 m x 2.5 m x 6 m (8 ft 

x 8 ft x 20 ft) ISO containers.

• Capable of rapid deployment in the field.

• Lift capacity of 23 t (25 ton) with quick acquisition of ISO container 

size loads

• Capable of rapidly constructing an airfield from pre-assembled, modular components. 

• Capable of performing a wide variety of other material handling tasks 

such as acquiring, moving and placing munitions, fuel/water tanks and 

palletized cargo. 

• Capable of carrying out a variety of other combat engineering tasks 

such as digging trenches, drilling holes for footings, berming and 
Key Words

4 of 65 CONTRACT SPECIFICATIONS

clearing trees.

The overall long term goal of this project is to develop and field-demonstrate a full scale prototype crane. 

* 1 t (metric ton) = 1000 kg
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Intelligent Systems Division 5 of 65

ATEC DESIGN CONFIGURATIONS

Container Mobilizer

Concept and Capabilities

Our conceptual design for the ATEC - Container Mobilizer is based on 

existing mobile gantry cranes (see Figure 1). Although our target capacity is 23 t (25 ton), we have chosen a structure more closely sized to a 45 

t (50 ton) crane to compensate for the rugged requirements of rough terrain. However, our main structural members, hollow box beams, would 

be fabricated from high strength aluminium instead of steel to lower the 

overall weight while maintaining structural integrity. In addition, our 

ATEC’s structural members can telescope within other hollow members 

to allow the complete structure to retract itself, while staying basically 

intact, to fit into an ISO container for transport.

FIGURE 1. 1/12th Scale Model of the ATEC - Container Mobilizer
Container Mobilizer

6 of 65 ATEC DESIGN CONFIGURATIONS

The Container Mobilizer is powered by a single diesel engine mounted 

on one of the crane’s side frames. Power is dispersed throughout the 

crane via hydraulic lines and hoses safely located within the hollow 

structural members. Hydraulic fluid and diesel fuel are also housed in 

tanks located within the lower structural members of the crane. The 

hydraulic lines power all four drive wheels, the steering motors, eight 

heavy duty winches for container stability and six lighter duty winches 

for Stewart Platform (Stewart, “A Platform with Six Degrees of Freedom,” The Institution of Mechanical Engineers, vol. 180, Part I, No. 15, 

pp. 371-386, Proceeding 1965-1966.) control to perform additional tasks. 

Auxillary hydraulic power ports will be located in the front and rear of 

the crane to provide power for tools such as spreader bars, drills, excavating equipment and saws.

In order to improve maneuverability while reducing the Container Mobilizer’s ground pressure under heavy loads, 1.83 m (6 ft) diameter wheels 

are mounted outside the frame on vertical pillars allowing 120° of rotation about each leg. This innovation will greatly improve the Container 

Handlers steering capability while approaching and mobilizing ISO containers. Several steering modes are available to the operator: 4 wheel 

steering on a 6 m (20 ft) radius, “spin-on-a-dime” steering, and side-toside (crab) steering as well.

Operator controls can be plugged into the front or rear of the ATEC - 

Container Mobilizer to provide the best vantage point. The portable operator panel will permit teleoperation of loads and control of the hydrostatic drive, similar to standard mobile gantry cranes.

The ATEC - Container Mobilizer is designed to straddle a standard 2.5 m 

x 2.5 m x 6 m (8 ft x 8 ft x 20 ft) ISO container weighing up to 23 t (25 

ton). It can pick or place a container on the ground, a flat-bed truck, or on 

top of another ISO container. The ATEC can pick up the container from 

the top or bottom ISO locks using a rectangular spreader bar. Once 

acquired, the ATEC - Container Handler can maneuver the container with 

6 Degrees-of-Freedom (DoF) control and stability. 

The container handler’s dexterity is such that it can stably place the container on two pedestal locks located at the base of two of the crane’s side 

legs. Once resting on these pedestals, the ISO container is then engaged 

via it’s upper ISO locks by two twist pins protruding from the top of the 

same legs. The attached cables (through the spreader bar) completely 

constrain the container and provide redundancy during mobility. The 

ATEC can then mobilize the ISO container with more than 0.9 m (3 ft) 

ground clearance while traveling at speeds of up to 16 km/h (10 mph) 

Higher speeds are possible with a larger engine and drive system gear 
Final Report: Air Transportable Expeditionary Crane Project

Intelligent Systems Division 7 of 65

changes. 

By attaching the spreader bar to the container bottom, stacking is 

achieved by allowing the container to hoist up through the crane frame to 

the height as shown in Figure 2. 

FIGURE 2. ATEC - Container Mobilizer showing Stacking Capability

The ATEC - Container Handler will weigh approximately 10.6 t (11.5 

tons) including additional components for reconfiguration into an ATEC - 

Cantilevered Material Handler. By packaging the ATEC into a MILVAN 

ISO Container weighing 2.2 t (2.4 tons), the total shipping weight of the 

ATEC is 12.7 t (14 tons). That is light enough to be transported by helicopter.

Other ATEC capabilities include the attachment of grippers or other 

material handling equipment to the spreader bars for doing: equipment/

vehicle maintenance, flexible fixturing, and material handling of breakbulk (miscellaneous small cargo). By attaching saws to the spreader bars, 

the user can adapt the ATEC to cut and remove trees and debris.

Additionally, the ATEC - Container Mobilizer can perform functions 

such as berming and excavation with a high speed digging tool, similar to 

a trench digger, attached to a triangular spreader bar. By running the digging arm along the ground using teleoperative control of the platform/

tool, the operator can carve earth in the exact location desired. Pushing or 

scraping earth is possible, by mobilizing a heavy container for ballast 

with a bull-dozer style blade attached to the spreader bar. The blade could 

then be controlled via teleoperation.
Container Mobilizer

8 of 65 ATEC DESIGN CONFIGURATIONS

Packaging/Deployment Sequence

The ATEC delivery will be via air transport while housed within a standard ISO 2.5 m x 2.5 m x 6 m 8 ft x 8 ft x 20 ft) ISO container (see Figure 3). Packaging will require unfastening and pivoting the wheels within 

the retracted gantry.

The engine and winches are on slides that are manually pulled-out and 

are fastened during deployment.

The container handling spreader bar breaks down, folds, and mounts to 

an upper frame location for stow while allowing the winches to remain 

attached and ready for quick deployment. Two triangular spreader bars 

can be fabricated from the container handling spreader bar. 

Components necessary to deploy the ATEC - Cantilevered Material Handler are also broken-down and fit within the packaged gantry and wheels. 

Items for this ATEC configuration are the: Boom, A-frame Vertical stay, 

winches, and support cabling.

The following is a procedure that describes the deployment steps shown 

in Figures 4 and 5. The bracketed numbers show the number of people 

times the approximate amount of time for each step.

Step 1 - Pull-out and attach ramps to container, attach unpacking winch. 

[2 people for 5 min]

Step 2 - Winch crane out of container and onto ramps. [1 person for 5 

min]

Step 3 - Safety check/engine start to warm hydraulic system, fill lines. [1 

person for 2 min]

Step 4 - Attach 4 jacks to frame (2 on each side). [8 people for 2 min]

Step 5 - Crank jacks to unload wheels, remove wheels from stow, jack to 

full height, attach wheels, remove jacks. [8 people for 10 min]

Step 6 - Slide out and secure winches and engine. [4 people for 5 min]

Step 7 - Attach hydraulic lines, drive front and rear wheels apart to telescope.[3 people for 2 min]

Step 8 - Rotate wheels 90° to “crab” position and drive apart to telescope 

to Container Mobilizer or Airstrip Construction Crane width. [1 person 

for 4 min]

Step 9 - Rotate wheels back, attach spreader bar or work platform and 

tool(s).[4 persons for 5 min]

Minimum total elapsed deployment time = 40 min*.
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Intelligent Systems Division 9 of 65

*Note: The approximate step timing is simply a measure estimated by the 

researchers. No basis is given for these time estimates. Therefore, a conservative deployment time estimate of less than one hour is feasible. With 

fewer people, the time estimate will increase.
Container Mobilizer

10 of 65 ATEC DESIGN CONFIGURATIONS

FIGURE 3. 1/12th Scale Model and Graphic Showing Packaged ATEC - Container Mobilizer 

19'

6' 10"

7' 2"

Side View

Top View

spreader bars (4)

triangular trusses (12)

ISO blocks for spreader (4)

A-frame hinges (2)

pulleys (12)

telescope pins (6)

spare cable reels (6)

5.8 m

2.1 m

2.2 m

ramps

heavy lift winches

frame

wheels

ISO Container
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Intelligent Systems Division 11 of 65

FIGURE 4. Deployment Sequence for the ATEC - Container Mobilizer (Steps 1 - 5). {side views}

Step 1

Step 2

Step 3

Step 4

Step 5
Container Mobilizer

12 of 65 ATEC DESIGN CONFIGURATIONS

FIGURE 5. Deployment Sequence for the ATEC - Container Mobilizer (Steps 6 - 9)

Step 9

 (top view)

 (top view)

Step 6

Step7

Step 8

Top

Top

engine

Side

Side

engine
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Intelligent Systems Division 13 of 65

Specifications

Structure The structure of the ATEC - Container Mobilizer is similar to a standard 

mobile gantry crane. Two rectangular structural frames made from 46 cm 

(18 in) aluminum box beams provide the major support. Members composing the frames are passively (as opposed to actively) telescoped in 

length to package the large frames within a standard ISO container measuring 2.5 m x 2.5 m x 6 m (8 ft x 8 ft x 20 ft) externally. 

A passively-telescoped (no added power required to telescope), widthexpansion member connects the two structural frames. The width member reduces from an 46 cm (18 in) box beam down to a 30 cm (12 in) box 

beam using five members. The ATEC - Container Mobilizer extends 4 of 

the 5 members, or reduces from an 18 in beam to only 36 cm (14 in) 

beam. The 36 cm (14 in) beam also houses the 30 cm (12 in) beam. For 

full width extension to 6 m (19’ 10”) structural width, the 30 cm (12 in) 

box beam is then extended.

The left frame connection is fixed with a series of bolts fastening two 

flanges. The right side is connected via a trunnion joint allowing the right 

frame to pivot, with respect to the joint, in the vertical plane. The joint 

allows wheel displacement in the vertical plane of ± 0.9 m (3 ft) or more 

allowing motion over rough terrain. This simple and effective joint creates little or no maintenance over the life of the crane. This joint is shown 

in Figure 6.

FIGURE 6. Cut-away view of Right ATEC Side Showing Fluid Storage Tanks

Vehicles The wheels are 1.8 m (6 ft) diameter x 0.5 m (1.5 ft) wide and are 

mounted on the outside of the frame. The design shown in Figure 7 

shows a portion of the leg fastened to a steering motor. The wheel then 

attaches to the steering motor housed within a heavy duty joint via a 

Diesel Fuel

Tank

Hydraulic Fluid

Tank

Length telescoping members trunion joint

40 gallon tanks

housed within 

structural member

retracted leg extensions

and steering motors

Engine

winches
Container Mobilizer

14 of 65 ATEC DESIGN CONFIGURATIONS

wheel connector with the hydraulical motor attached to the wheel. To 

attach the wheel to the leg during deployment (see Figure 8), the steering 

motor and leg extension telescopes from the frame and the wheel can 

then be attached for use.

FIGURE 7. ATEC Vehicle Design

FIGURE 8. Vehicle Attachment to the ATEC Leg

The wheel assembly, including the tires, drive (gear) motor, steering 

motors, wheels, and wheel connections, weighs approximately 1814 kg 

(4000 lb). The ATEC ground loading is approximately 289 kPa (42 psi) 

with a 23 t (25 ton) load evenly distributed across all four wheels. This 

leg (telescoping section)

wheel connector

drive motor

wheel

tire

disk brake

A-A' View Side View

A

A'

steering motor

Leg Telescope and Wheel Attachment
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Intelligent Systems Division 15 of 65

compares to the LACH (Lightweight Amphibious Container Handler) 

with approximately 483 kPa (70 psi) or the RTCH (Rough Terrain Container Handler) with more than 689 kPa (100 psi). 

Since there are four independently controlled wheels, multiple steering 

modes exist. They are as follows: 4 wheel steering on a minimum 6 m (20 

ft) radius, “spin-on-a-dime” steering, and side-to-side (crab) steering, as 

well as combinations of each.

Winches/Actuators Eight winches are used to control the suspended load (eg. spreader bars, 

ISO containers, tools, and equipment) in a RoboCrane® configuration. 

Figure 9 shows the cable configuration for the container handling 

spreader bar. The cables allow six DOF load control, whether using the 

container handling or triangular spreader bars. The triangular spreader 

bar cable configuration is similar to the standard Stewart Platform configuration. 

FIGURE 9. Container Handling Spreader Bar Cable Configuration

18 t vertical lift cables

(7 cable wraps) 

4.5 t cross cables

(3 cable wraps)

5.4 t end cables

(3 cable wraps)

upper container locks

(mounted to ATEC frame)

container mobilizer shelf (1 of 2)

• Upper cable ends contact pulleys.

• Spreader bar rests on shelves and latches to upper

 container locks.
Container Mobilizer

16 of 65 ATEC DESIGN CONFIGURATIONS

There will be two winch types: 1) A lightweight winch with line speed of 

0.46 m/min (90 ft/min) and pull capacity of 907 kg (2000 lb); 2) A heavy 

weight winch with line speed of 0.5 m/min (99 ft/min) and pull of 2630 

kg (5800 lb). A aariety of cable wraps will be used to achieve additional 

speeds and pulls. Sheaves are to be aluminum and easily accessible for 

changing cables and/or configurations in the field.

ATEC actuators consist of drive and steering gearmotors used for ATEC 

mobility. These drive systems are hydraulic planetary gearmotors as used 

in commercial mobile gantry cranes, with similar weight, size, speed, and 

durability.

Power System The power system is modeled from a standard mobile gantry crane and 

the single unit system designed during FY94 ATEC project. The ATEC 

power system consists of a four cylinder diesel engine, gear pump driven 

off the engine flywheel, hydraulic filter system, hydraulic oil cooler, 

hydrostatic transmission, and 0.15 m3 (40 gallon) diesel fuel and hydraulic fluid tanks. 

A John Deere ** 4039T diesel engine is specified and provides 76 kW 

(102 HP) at 2100 r/min for a standard 45 t (50 ton) mobile gantry crane 

(see ShuttleliftTM SL50 Specification Sheet - Appendix II). This same 

engine or it’s equivalent is specified for the ATEC. 

Control and actuation is provided to all wheel drives and their steering 

motors simultaneously. Similarly, all eight winches are controlled and 

actuated simultaneously. The ATEC could theoretically control all actuators simultaneously but, at a reduction in speed and performance.

Diesel fuel and hydraulic fluid are stored within the engine support structural member as shown in Figure 6. Storage within a structural member 

provides high puncture resistance and removes the need for additional 

tank storage volumes.

** The National Institute of Standards and Technology (NIST) does not 

endorse the products mentioned in this paper. These products are used for 

illustration purposes only and are not mentioned because they are better 

than another similar product.

Spreader Bar The Container Mobilizer spreader bar is packaged with the ATEC ready 

for deployment and use in container handling. During deployment, the 

spreader bar is manually assembled quickly and easily. The spreader bar 

is made from 10 cm x 1.3 cm (4 inx 1/2 in) wall box beam 6105-T6 aluminum with solid aluminum corners measuring 15 cm high x 30 cm long 

x 15 cm deep (6 in high x 12 in long x 6 in deep) as shown in Figure 10. 
Final Report: Air Transportable Expeditionary Crane Project

Intelligent Systems Division 17 of 65

Connection rods made from 13 cm (5 in) aluminum box beam x 1.3 cm 

(1/2 in) wall thickness and join the 2.5 m (8 ft 4 in) length members 

together with locking pins. A similar connection is made at the corners. 

As shown in cross-section view A-A’ in Figure 10, spreader bar connection to an ISO container requires automatic locking mechanisms controlled by a remote operator. This automatic connection acts similar to a 

solenoid for translating the ISO connector pin into the container during 

acquisition and rotates via a second solenoid automatically upon translation. This operation could be overridden for manual operation. The hoist 

ring is suspended from the lift cables and is connected to the ISO pin. 

Therefore, container lift is achieved at the container and not translated 

through the spreader bar corners. Therefore, lighter corners are possible. 

The Container Handling spreader bar weighs approximately 279 kg (616 

lb).
Container Mobilizer

18 of 65 ATEC DESIGN CONFIGURATIONS

FIGURE 10. Container Mobilizer Spreader Bar

Top View

Side View

Top View - A-A'

A'

hoist ring

Step 1 Step 2

10 cm square x 1 cm wall th.

Aluminum Tubing

2.9 m

(9 ft 8 in)

6.4 m

(21 ft)

A

aluminum tubing

twist lock

see Top View- A-A' below

for pin connection-tocontainer close-up

Step 1: push twist lock into container ISO connector

Step 2: rotate twist lock to lock ISO connector to spreader bar
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Intelligent Systems Division 19 of 65

Cantilevered Material Handler

Concept and Capabilities

The ATEC - Cantilevered Material Handler (CMH) is a reconfiguration 

of the ATEC - Container Mobilizer (See Figure 11). All components of 

the ATEC - CMH can be packaged and contained within the same shipping container carrying the ATEC - Container Mobilizer. The ATEC - 

Cantilevered Material Handler has two working platforms.

The forward platform is designed to maneuver loads of up to 680 kg 

(1500 lb) while at a reach of up to 9.1 m (30 ft) from the ATEC’s main 

structure. With a load of 680 kg at 9.1 m, the ATEC-CMH has a safety 

factor of 5 against tipping. Similarly, 680 kg supported by the ATECCMH at 3 m (10 ft) outside the wheel base (see Figure 12) constitutes a 

safety factor of 18 against rolling over.

FIGURE 11. Side View of the ATEC - Cantilevered Material Handler showing Cantilever System

A cantilevered boom pivots horizontally about the ATEC width member 

center point. Cables from the ATEC - Container Mobilizer winches are 

rerouted over sheaves at the ATEC - CMH boom tip and ATEC front, top 

frame corners and from there to a triangular spreader bar. The triangular 

spreader bar can then be controlled as a Stewart Platform parallel link 

manipulator. Loads can be maneuvered at full winch speeds (30 m/min 

(99 ft/min) cable speed). An additional pair of winch cables are used for 

steering the boom. Steering the boom allows the suspended platform to 

move about a large area while providing six DOF position control of the 

load. See Figure 12 for a top view.

3.8 m

16.5 m

7.0 m
Cantilevered Material Handler

20 of 65 ATEC DESIGN CONFIGURATIONS

FIGURE 12. ATEC - Material Handler boom components and work volume

To prevent counterbalance for boom compression into the width telescoping member, a push-rod supported by two truss cables is mounted to the 

boom rear with truss cable attachment at the width telescoping member 

ends. To provide boom lift, a vertical stay A-frame is attached to the 

width telescoping member near the front legs. Fixed length truss cables 

Top View Showing Additional Members

Top View showing Boom Swing Limits

7.3 m

8.9 m

3 m

3 m
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Intelligent Systems Division 21 of 65

then attach from the A-frame to the boom tip and from the A-frame to the 

ATEC top, rear members. Also, a lightweight fixed length truss cable is 

attached from the A-frame to the push rod end to support the rod weight. 

Therefore, the boom is held in a horizontal plane while sweeping an arc 

of ±45°, reaching a width of over 12 m (40 ft), and providing no bending 

moments in the ATEC width-telescoping member or the legs. A maximum loading of 680 kg (1500 lb) cantilevered from the boom causes a 

horizontal force on the A-frame followed by a tension in the rear truss 

cables. This tension also adds a force to the ATEC rear legs of up to 

13,345 N (3000 lbf) but, the force is negligible due to the structural 

strength of the ATEC leg frames.

FIGURE 13. Winches Mounting Location

Six additional, lightweight winches are then attached to the ATEC beside 

the heavy lift winches (see Figure 13). These winches are then routed 

over the ATEC - Container Mobilizer configured sheaves (only using one 

sheave from the block and tackles) to form a Stewart Platform configuration upon suspending another triangular spreader bar to these cables. 

Loads of 680 kg (1500 lb) can be maneuvered and controlled by the 

ATEC rear winches for rapid simultaneous construction applications such 

as airstrip construction. 

Control modes for the ATEC - CMH are teleoperation and semi-autonomy.

Light-duty, Rear

Stewart Platform

Heavy-duty, 

Winches

Container Handling 

Winches
Cantilevered Material Handler

22 of 65 ATEC DESIGN CONFIGURATIONS

Packaging/Deployment Sequence

ATEC - Cantilevered Material Handler deployment involves a multistep 

process (see Figures 14 and 15). The following is a description of the 

deployment procedure shown in the figures. The bracketed numbers show 

the number of people and the approximate times each step should 

require. Estimated times are based on an eight person team performing 

some steps concurrently and others sequentially. If fewer people are 

available, estimated times will increase.

Step 1 - [10 min] Place all A-frame trusses, parts and tools on top of 

ATEC transfer container and assemble A-frame trusses [4 people]. The 

ISO container will act as a platform for 4 people to perform the following 

modifications. Meanwhile, telescope ATEC frame width from 5.4 m (17 

ft 10 in) to 7.2 m (23 ft 7 in) and approach storage ISO container from 

broad side [2 people]. Begin assembly of boom on ground in front of 

container door [4 people].

Step 2 - [10 min.] Secure telescoping member with push-pins [2 person], 

attach A-frame hinges and pivot pin reinforcement [2 people], and runheavy lift cable from rear winches to A-frame tip [4 people].

Step 3 - [5 min.] Lift A-frame into hinge position and drive hinge pins [4 

people], place temporary truss post under A-frame tip for support [1 person], attach three fixed length boom support cables to A-frame tip along 

with a winched boom placement cable [1 person].

Step 4 - [5 min.] Hoist A-frame up overhead [4 people] and winch in 

heavy lift cable until taut [1 person]. Leave A-frame leaning forward 60° 

from vertical. Remove support post.

Step 5 - [5 min.] Back ATEC away from broad side of container and 

straddle container from closed end so the assembled boom is in front of 

crane and directly under leaning A-frame.

Step 6 - [15 min.] A) Hoist boom and push-rod assembly (with hinge 

locked). B) Continue hoisting toward the leaning A-frame apex allowing 

the boom tip to ride along the ground on it’s imbedded wheel [1 person]. 

C) Once the push rod has cleared the telescoping frame member, raise the 

angle of the A-frame back toward vertical until the push rod tension 

cables can be attached from the A-frame hinges to the rear of the pushrod [4 people]. D) Attach the three remaining boom support cables which 

are dangling from the A-frame apex and winch in the A-frame until it is 

vertical [3 people]. Then lower the boom over the pivot hole in the telescoping frame member and drive the pivot pin into place [2 people].
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Intelligent Systems Division 23 of 65

FIGURE 14. Deployment Sequence for the ATEC - Cantilevered Material Handler (Steps 1, 4, 5)

24'

Step 1 - Top View

Step 4 - Side View

Step 5 - Top View
Cantilevered Material Handler

24 of 65 ATEC DESIGN CONFIGURATIONS

FIGURE 15. Deployment Sequence for the ATEC - Cantilevered Material Handler (Steps 6 and 7)

Step 6b

Step 6d

truss boom extension

pivot pin (retracted)

A-frame

Step 6 - Side View

Step 6a

Step 6c

Step 7 - Side View
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Step 7 - [Concurrent with Step 6] Run six light duty cables for cantilevered platform and attach assembled triangular platform [2 people].

Estimated elapsed deployment time = 50 min.

Specifications

Structure The structural members for the ATEC - CMH are an aluminum triangular 

truss boom, an A-frame truss, and a compression push-rod. The boom is 

7.5 m (30 ft) in length and is attached to the width telescoping member 

through a pivot joint. The boom end provides a point for two cables of the 

Stewart Platform to suspend and complete the triangle or to suspend 

loads from the end point similar to a tower crane. The advantage of this 

design is to allow the ATEC to be positioned on a stable or finished area 

while working in front of the crane, such as over ravines and waterways, 

and for building airstrips. 

The A-frame is a structural truss configured to provide nearly pure compression forces on the legs and tension in the width telescoping member 

while only small bending moments are evident. Truss cables from the 

boom to the A-frame and A-frame to the crane rear, provide additional 

forces on these members to counterbalance their weights, boom end loading, and static and dynamic forces that occur during use.

The push-rod provides a pure compression to counterbalance boom loading that can be up to 3765 kg (8300 Lbs.) while the boom lifts 680 kg 

(1500 lb) The push-rod is supported by truss cables that extend from the 

push-rod end to the width telescoping member ends. 

The total weight of all structural members is approximately 356 kg (785 

lb)

Winches Rear ATEC winches are specified as Braden model PD5A-29012-01 

winches with the following characteristics: 27 m/min (90 ft/min) first 

layer wrap speed, 30 L/min (8 gal/min) system flow, 680 kg (1500 lb) 

line pull, and the system pressure of 10.3 MPa (1500 psi) and a gear ratio 

of 29:1. 

Cabling Winch cables measuring 8 mm (5/16 in) diameter are 8 x 25 Extra 

Improved Plow Steel (EIPS) with 4.2 t (4.63 tons) nominal strength. Tensions in the push-rod cables experience up to 3402 kg (7500 lb) and are 

therefore 15.8 mm (5/8 in) diameter 8 x 25 EIPS cables, with nominal 

strength of 16.4 t (18.1 tons) providing a 4.8 safety ratio. Rear truss 

cables experience 18.7 kN (4200 lbf) tension each requiring 12.7 mm (1/
Airstrip Fabrication

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2 in) diameter, 8 x 25 EIPS cables with nominal strength of 103 kN (11.6 

ton-f) providing a 5.5 safety ratio. The boom truss cable experiences 37 

kN (8316 lbf) tension requiring two, parallel, 12.7 mm (1/2 in) diameter, 

8 x 25 EIPS cables with nominal strength of 103 kN (11.6 ton-f) each 

(206 kN total (23.2 ton-f )) providing a 5.6 safety ratio. The total weight 

of these cables is 54 kg (120 lb) with end connections.

Airstrip Fabrication

A main capability of the ATEC - Cantilevered Material Handler (CMH) 

is airstrip construction. Construction of the airstrip using modular components, such as the 10-A, Inc. Modular Bridging Structure (MBS), is a 

rapid process whereby components are brought to the site, stacked in 

last-in, first-out order, which can be rapidly picked and placed by the 

front and rear Stewart Platforms. 

FIGURE 16. ATEC - Container Mobilizer and Cantilevered Material Handler Assemble Runway
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Components can be brought to the site with ATEC - Container Mobilizers 

or other material handlers, while the ATEC - Cantilevered Material Handlers fabricate the airstrip (see Figure 16). 

Figure 17 shows the front spreader bar grabbing a component from the 

airstrip edge. At this position the ATEC - CMH can reach stacked components and maneuver them into position with 6 DoF. Simultaneously, the 

rear spreader bar can install deck plates with 6 DoF control.

FIGURE 17. ATEC - Cantilevered Material Handler 

Drills can also be attached to an ATEC to drill at airstrip leg locations to 

provide anchoring for the legs. Figure 20 shows a model of the drills 

attached to the ATEC to depict this scenario.
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28 of 65 ATEC DESIGN CONFIGURATIONS

Airstrip Assembly 

Assumptions Although the ATEC can provide functions such as drilling footings, timings were not estimated as part of an airstrip assembly sequence. An 

assembly procedure was developed to show feasibility and give a rough 

estimate of the required speed of crane operations. Table 1 shows the 

worst case component weights. 

Using the 10-A ATA component abbreviations (see 10A ATA interim 

report), these components consist of: Deck Truss (DT), Transverse Truss 

(TT), Connector Transverse to Transverse (CTT), Connector column to 

CTT (CCTT), and Connector feet to column (CCL).

A series of assumptions were made:

• Airstrip components will arrive at the site packaged as 6 m x 2.5 m x 

2.5 m (20 ft x 8 ft x 8 ft) ISO pallets. Since packaging criteria will 

emphasize stacking and volume minimization we can not assume that 

components are placed optimally for construction purposes. The 

ATEC will unpack the containers, deliver material to the construction 

site, pre-assemble components, install the footings, and construct the 

airstrip superstructure.

• The construction crane can drive and swing the boom while carrying 

the load.

• It takes at least 5 min to clear the ground and place each footing 

including anchors.

• At the beginning of the airstrip construction, ATECs are assembled 

and ready for operation. 

• Material can not always be placed inside the construction zone. During construction with no columns or low columns, the material would 

be in the way, obstructing component placement. 

TABLE 1. Worst Case 10A Airstrip Component Weights

AIRSTRIP COMPONENT MASS (kg)

DT 680

TT 680

DK - 4 x 20' 227

DK - 2 x 20’ 113

Column + CCTT + CTT 680
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• DTs, TTs, decks and columns are assumed to be oriented along the 

airstrip in order to place the component’s c.g. closer to the construction site and reduce the required length of the crane boom. 

• Columns and CCTTs come pre assembled in the ISO containers

• The ATEC spreader bars are equipped to permit the DTs to be rotated 

at least 90° in the horizontal plane and the columns to be rotated at 

least 90° in the vertical plane. Columns can be picked up and rotated 

into a vertical position in order to be installed. DTs can be picked up 

from the side and rotated into position.

• Pick and place times for different components are assumed to be 

roughly the same. Each pick/place is estimated as one operation, pick 

counts as half an operation, place counts as half an operation. Load 

movement and crane travel times are either negligible or averaged into 

the pick/place time.

Some off-line assembly is assumed to speed airstrip construction because 

some of the assembly tasks can be performed in parallel with other tasks. 

While pre-assembly must be performed, doing it off-line is optional. If 

we assume off-line assembly we can unpack and repack components and 

pre-assemble submodules to optimize material delivery to the construction process. The following subassemblies will save significant time if 

they are done off-line.

• Pre-assemble the Column/CCTT, CTT and 0.6 m x 1.2 m (2 ft x 4 ft) 

Deck.

• Pre-assemble the TT and the 0.6 m x 6 m (2 ft x 20 ft) Deck.

Off-line construction has several drawbacks, such as: a staging area is 

required, material must be delivered from the staging area to the construction site over rough terrain, additional equipment and/or personnel 

will be required. These considerations must be weighed in deciding 

whether to rely on off-line assembly and delivery to the construction site. 

If enough cranes are used, it may be possible to avoid these difficulties by 

delivering airstrip components directly along the airstrip sides and performing the pre-assembly at the construction site.

Assembly Sequence and 

Timing The timing sequence specified here is designed to demonstrate construction at the rate of 6 min per 7.3 m (24 ft) of airstrip length. Any ATA 

assembly sequence that can be completed in 10 h or less would clearly 

require coordinated parallel efforts between all the task definitions above 

regardless of whether the process uses a Robocrane or any other form of 
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30 of 65 ATEC DESIGN CONFIGURATIONS

automation. Some complexity in coordination of the required effort can 

not be avoided.

The airstrip is 15.2 m x 274 m (50 ft x 900 ft) and will consist of 40 modules. Modules are 7.3 m (24 ft) long (including columns) but decks are 

only 6 m (20 ft) long. Two modules wide, including a third column, 

makes up the 15.2 m (50 ft) width. Therefore, 6 decks must be placed for 

every 5 modules. The rear crane is dedicated to laying decks and should 

be able to perform the operation simultaneously.

Two assembly scenarios have been completed.

Scenario 1: One ATEC does the entire assembly. This is not a reasonable 

option but it is useful for comparison purposes. The sequence for Scenario 1 is as follows:

• ATEC front platform places 2 column/CTTs and 2 TT/DK2x20s 

• ATEC front platform places 3 DTs 

• ATEC rear platform places 6 DK4x20s, simultaneous to front platform.

• ATEC backs up far enough to move to the other side of the airstrip

• ATEC front platform places 1 column/CTTs and 1 TT/DK2x20

• ATEC front platform places 3 DTs

• ATEC rear platform places 6 DK4x20s, simultaneous to front platform.

The total time to perform this operation is 6.7 h, with 52 s for each pick, 

move, and place maneuver.

Scenario 2: Two ATECs do the entire assembly. ATECs A and B are on 

different sides of the air strip. Crane B is at least one module behind 

crane A. The sequence for Scenario 2 is as follows:

• 1a front. ATEC A front platform places 2 column/CCTTs and 2 TT/

DK2X20s

• 1b front. ATEC B front platform places 1 column/CCTTs and 1 TT/

DK2X20s

• 2a front. ATEC A front platform places 3 DTs

• 2b front. ATEC B front platform places 3 DTs

• 1a rear. ATEC A rear platform places 6 DK4x20s, simultaneous to 

front platform.

• 1b rear. ATEC B rear platform places 6 DK4x20s, simultaneous to 

front platform.
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The total time to perform this operation is 4 h, with 52 s for each pick, 

move, and place maneuver.

Utilities

Spreader Bars

Spreader bars are necessary for allowing 6 DoF control of the load for a 

variety of applications. Figure 18 shows the Triangular Spreader bar configuration made from the Container Mobilizer spreader bar shown in Figure 10. Two spreaders can be made from the Container Mobilizer 

spreader bar, measuring 2.5 m (8 ft 4 in) equilateral, and are used during 

applications such as: excavating, berming, drilling, sawing, vehicle maintenance, and airstrip construction. The joints of the spreader bar are hinge 

joints whereby the hinge pins are also eye bolts for cable connections. 

The Triangular spreader bars weigh approximately 98 kg (217 lb) each.

FIGURE 18. Triangular Spreader Bar

Digging Tools

Figure 19 shows two types of digging tools that can be used, A) a high 

speed digging arm, and B) a bull-dozer style blade for scraping. Both 

concepts are practical. The high speed digging bar is similar to a chain 

saw typically used to dig trenches rapidly. The same arm could be used to 

dig trenches, construct berms, or dig footings. Power for the digging arm 

is available from an ATEC optional hydraulic port. 

Top View

Side View

 2.5 m 8' 4"
Utilities

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By lifting a loaded container and suspending the container from the 

cables (i.e. not rested on the shelves, a scraping blade can be attached to 

the spreader for doing excavation, berming, and scraping. This configuration requires no additional power from the ATEC. 

FIGURE 19. Earth Moving Optional Tools 

Other Tools

Other tools such as: drills, saws, and grippers, provide a variety of applications the ATEC can perform. For drilling, high speed drills can be 

attached to the optional hydraulic power ports and mounted on the container shelves for drilling holes for footings or posts. Figure 20 shows an 

ATEC model depicting this scenario.

ground container handling 

spreader bar

loaded ISO container

bull-dozer style blade

B Partial Side View

high speed

digging arm

triangular 

spreader bar

Side View

ground

A
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FIGURE 20. Scale Model ATEC Drilling Footing Anchor Holes

Chain saws can be attached to the triangular spreader bar and powered by 

ATEC hydraulic power for felling trees or clearing brush and debris. 

Grippers can be attached similarly for material handling of break-bulk 

loads and vehicle maintenance. Loads of up to 23 t (25 ton) can be lifted 

and maneuvered with 6 DOF. Both tools and grippers can be operator 

controlled using teleoperation with a simple joystick.
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Model Photos

The following is a series of photographs showing scale models built as a 

proof of concept for the Phase II ATEC Project:

1. 1/12th Scale model of the packaged ATEC.

2. 1/12th Scale model of the ATEC being deployed. Silver boxes on side 

represent winches.

3. 1/12th Scale model of the ATEC out of the container and ready to 

deploy jacks.

4. Top view of the 1/12th scale model out of the container and ready to 

deploy jacks.

5. Side view of 1/12th scale model ATEC handling/mobilizing a container.

6. Front/side view of ATEC performing container handling/mobility.

7. 1/12th Scale model ATEC performing side-to-side mobility to align a 

container with another for placement.

8. Close-up of1/12th scale model showing spreader bar connection to 

container and “shelf” type connection of spreader bar to ATEC.

9. Close-up of 1/12th scale model spreader bar connected to container 

and ready to place on “shelf” type ATEC connection.

10. ATEC 1/12th scale model showing container ready to be stacked on 

another container.

11. ATEC 1/12th scale model showing container stacking on another container. Note roller for container edge guidance.

12. ATEC 1/12th scale model showing container stacking on another container.

13. ATEC 1/12th scale model ready to attach spreader bar to top of container since no access is available to bottom ISO locks.

14. ATEC 1/12th scale model with spreader bar attached to top container 

ISO locks and ready to lift.

15. ATEC 1/12th scale model ready to straddle and grab a flat-rack ISO 

container.

16. ATEC 1/12th scale model performing drilling operation.

17. ATEC-CMH 1/12th scale model showing boom support structure.

18. ATEC-CMH 1/12th scale model maneuvering dual work platforms.
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19. ATEC 1/12th scale model supplies deck plates while ATEC-CMH 

constructs airstrip.

20. ATEC 1/12th scale models showing relative sizes. Multi-colored runway components show outside dimension sizes only.
Model Photos

36 of 65 ATEC DESIGN CONFIGURATIONS

If you would like to see the photos, please e-mail Debra Russell for a 

hard copy of this paper. Her e-mail address is debra.russell@nist.gov.
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DETAILED SPECIFICATIONS

TABLE 2. ATEC Weights

ITEM

UNIT 

MASS QTY.

TOTAL 

MASS 

(kg) (kg)

CONTAINER

MOBILIZER

Gantry 1566 1 1566

Engine/housing 453 1 453

fuel/hydraulic fluid 3.6 80 290

tires 435 4 1742

drive systems 340 4 1360

steer motors, brakes 226 4 907

wheels 264 4 1058

wheel joints 136 4 544

winches/servo valves 77 8 617

cables 161 1 161

sheaves 8 40 320

hydraulic hose 327 1 327

spreader bar 317 1 317

controls/computer 45 1 45

CANTILEVERED

MATERIAL HANDLER

ADDITIONS:

structural components 431 1 431

boom steer motor, brake 226 1 226

lt. duty winches, sheaves 27 6 163

rear truss cables 5 1 5

 TOTAL

ATEC 

MASS 10,532

MILVAN Cargo Container 2163

TOTAL

SHIPPING

MASS 12,696
Weight Analysis

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Weight Analysis

The ATEC - Container Mobilizer weight can be broken down into components as shown in Table 2. The above table shows the major systemcomponents for both the ATEC - Container Mobilizer and Cantilevered 

Material Handler with a total weight of 10.5 t (11.6 tons). This weight is 

inclusive of all materials to be shipped in a single container. Including the 

MILVAN - General Cargo Container, the shipping weight then totals 12.7 

t (14 tons). Estimates were made for most ATEC components based on 

the: FY94 weight analysis, research, and calculations using known materials and dimensions. Therefore, the table should be used as an estimate 

of component weights. With extended research, lighter and more accurate 

component weights can be included in the ATEC design.

Cost and Fabrication Time

The cost of a current mobile gantry crane can be approximated at 

$173,000 including the following standard features: 

• 6 m x 6 m (20 ft x 20 ft) inside clearance area,

• 6 m (21 ft) wheelbase, 

• diesel engine, 

• steel structure with approximately 0.4 m (18 in) box steel beams, 

• 4 wheel drive, 

• and 45 t (50 ton) capacity. 

A standard 23 t (25 ton) capacity mobile gantry crane with the above features can currently be purchased at approximately $118,000. NIST estimates, based on these standard cranes, that the 23 t (25 ton) capacity 

ATEC with all features described within this document referring to both 

the ATEC - Container Mobilizer and Cantilevered Material Handler configurations, will cost approximately $200,000 during mass production.

Fabrication time of standard mobile gantry cranes are on the order of one 

piece within 90 days or 100 pieces fabricated in 13 months. Comparative 

estimates for the ATEC fabrication time can be assumed since standard 

inventories will include the ATEC once prototype stages are complete.
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Industry Contacts

During the course of the ATEC project, we contacted several industrial 

equipment vendors to research assorted crane designs, components and 

applications. These contacts provided background in current crane 

designs and materials used so we could determine the current state of the 

art in crane design. Also, contacts provided the relative trade-offs 

between cost and availability of specific crane components that we chose 

to include in our ATEC design. And finally, some of our contacts were 

with civilian and military crane/material handling operators in order to 

determine the capabilities of current material handling equipment and the 

needs of mobile crane operators.

A list of our contacts follows:

• ShuttleliftTM, Inc.: John Kacmarynski, Ken Davis, and Tom Feider 

provided mobile gantry crane expertise, pricing and delivery times.

• Robotics Technology, Inc.: Bob Finkelstein and Joe Eisman provided 

technical expertise in the area of robotics and automated systems.

• 10A Inc.: Yair Tene and Noam Tene provided airstrip component 

specifications. 

• Drehtainer Technik/Forschler and Assoc.: Helmut Meyer/George 

Forschler presented the Lift-Tainer 

• Bridgestone/Firestone Off Road Tire Co.: Jack Dutcher provided 

tire sizes and weights.

• Titan Wheel Co.: David Cool provided specifications on wheel 

designs, rims, hubs including pricing and weights.

• Shulmar, Inc.: Ray Saunders provided leasing and site visit information for a mobile gantry crane.

The project team visited U.S. Marine Corps Camp LeJeune in Jacksonville N.C. (June 1995). We toured their facility and inspected the Marine 

Corps current inventory of cargo handling equipment along with the 

other partners working under Expeditionary Engineering contracts. 

Some of the cargo handling equipment available for demonstrations were 

the RTCH, TRAM, EBFL, and DTC. These assorted cargo handlers varied greatly in their size and capacity. The largest of the inventory, by far, 

was the RTCH which can lift, manipulate and mobilize loaded ISO containers as a front-end-loader. The RTCH has the drawback of being 

heavier (47 t (52 tons)) than the cargo it is lifting since it relies on a counterweight for balance. It is therefore not helicopter transportable, which is 
Industry Contacts

60 of 65 Detailed Specifications

an ATEC requirement. The other equipment ranged from extended boom 

fork lifts, such as the TRAM, which are useful for manipulating empty 

containers to the EBFL (4.5 t (5 tons) capacity) and the DTC which has a 

1.8 t (2 tons) capacity and fits inside an ISO container. The latter three 

were all helicopter transportable but for loaded ISO container handling 

operations, especially in rugged terrain, the RTCH was the only game in 

town. 

We also saw a dolly set lift transportable container mobilizer which is 

manually attached to each end of a container by 4 marines in less than 

and hour. This dolly set was interesting because of its minimal design. It 

utilized the structure of the container and simply jacked the container up 

off the ground by forcing the wheels from either end of the container up 

against the container. The model we saw acted solely as a trailer and had 

no onboard power or active steering. However, the idea of using the rigidity of the container structure was interesting to us and we tried to utilize 

this concept in our mobilizer design.

The project team also visited the Occaquan River Marina to observe 

operations of a Travelift 23 t (25 ton) mobile gantry crane as it performed 

heavy-lift cargo handling tasks. The cargo being manipulated at this 

marina were, of course, boats. However, we saw the mobile gantry crane 

traverse unimproved surfaces under heavy loads. We have since based our 

ATEC design on mobile gantry cranes such as this due to their relatively 

lightweight structure, simplicity of design, and maneuverability.
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RECOMMENDATIONS

Based on the information presented in this document, it is our recommendation that the ATEC include the following design features: 

ATEC - Container Mobilizer:

• The ATEC will look similar to Figure 1. It will include four independently controlled wheels and eight independently controlled winches 

acting upon a spreader-bar. It will deploy from one 6 m (20 ft) ISO 

Container, weighing 14.5 t (16 tons) or less, deploy in the field, and be 

controlled via teleoperation or master/robot (walk along) control.

• It's capacity is 22.7 t (25 tons) maximum for 6 m (20 ft) ISO container 

size loads. Container mobilization, and many other applications can be 

completed as designed.

• The ATEC will move at a rate of 16 km/h (10 mi/h) or more; speed is 

application dependant.

• Eight or fewer Marine Corps. personnel can erect the crane in approximately 40 min; fewer personnel will require more time. 

• Control is intuitive; personnel with limited training will have full 

crane functionality available.

ATEC - Cantilevered Material Handler

• Reconfigurability of the ATEC - Container Mobilizer(see Figures 16 

and 17) into an ATEC - Cantilevered Material Handler can be completed as designed and deployed in the field. 

• It will have a farthest reach (9 m (30 ft)) capacity of 680 kg (1500 

Lbs.) and traverse at winch speeds of up to 27 m/min (90 ft/min). 

• It will have two RoboCranes, one cantilevered, a second within the 

mobilizer frame. These can be operated simultaneously. A rear 

spreader bar and the cantilevered spreader bar will have 6 DoF control 

using teleoperation of each from a joystick.

• Eight Marine Corps. personnel can erect the crane in less than one 

hour from an ATEC - Container Mobilizer; fewer personnel will 

require more time.

• Control is intuitive; personnel with limited training will have full 

crane functionality available.
FY97 Proposal

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FY97 Proposal 

(The following proposal is directly from the FY95 Final ATEC Project 

Report)

During fiscal year 1997, NIST proposes the following tasks be performed 

by NIST and other sub-contractors so as to move the ATEC technology to 

Phase III:

1. Specify and procure or lease a Shuttlelift or comparable mobile gantry 

crane with 23 t (25 ton) capacity and hydraulic power, winches and fourwheel drive systems, all cabling, sheaves and necessary hardware. [2 

man-months]

2. Modify the crane control system to allow for coordinated control of all 

eight winches similar to the Robocrane®. [3 man-months]

3. Develop a container handling spreader bar similar to the Phase II 

design previously described. [2 man-months]

4. Demonstrate: container handling of ISO container size loads over 

uneven terrain and stacking of ISO containers. [2 man-months]

5. Design, construct and demonstrate a full scale ATEC - Cantilevered 

Material Handler using the mobile gantry crane base system. [2 manmonths]

6. Procure six additional winches and provide simultaneous coordinated 

control of front and rear platforms. [4 man-months]

7. Develop alternative concepts for performing expeditionary tasks 

within the OMFTS arena. [1 man-month]

Total NIST Labor during FY96: $230k

Materials for the project will include: leasing a mobile gantry crane with 

8 heavy lift winches, and procuring 6 lightweight winches, structural elements, amplifiers, and miscellaneous items.

Approximate Materials Total: $110k*

TOTAL $340k

*with a crane lease totaling $60k.
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FY98 Proposal **

Design, fabricate and demonstrate a full scale 23 t (25ton) capacity ATEC 

prototype. It will demonstrate packaging, deployment, container mobilization, Stewart Platform tool/equipment manipulation and teleoperative 

control capabilities. Table 3 shows a basic cost outline for the project:

TABLE 3. FY97 Proposed Cost Outline for a Full-Scale Prototype ATEC

MATERIALS

ITEM UNIT COST ($K) NO. TOTAL

Base Frame, Power, Vehicles 150 1 150

Winches, cables, sheaves 8 8 64

Winches, cables, sheaves 6 3 18

Computer 15 1 15

Electronics, Amps, Sensors 25 1 25

Miscellaneous 10 1 10

Sub-Total: $282k

LABOR: TIME (MM)

Planning 2

Procurements 3

Design 6

Fabricate 6

Software 5

Electronics/Hydraulics 6

Integration 3

Testing 4

[Labor @ $175k/year] 35 x $14.6k: $511k

Total: $793k
Phase I Report

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APPENDIX I 

Phase I Report

The following document is a copy of the Phase I ATEC Final Report. 

(Copies of the unpublished Phase I ATEC Final Report are available upon 

request.)
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APPENDIX II 

• The following are specifications for a mobile gantry crane and 

winches. These components significantly added to the design concept 

and are included in this report as additional information. The specifications are as follows:

• ShuttleliftTM SL50 Specification Sheet

• ShuttleliftTM SL25 Specification Sheet

• Braden 5.8A Hydraulic Winch Series

(These documents are unpublished and are available upon request from 

NIST or the vendor.)