What is a Variable Ballast?

The main function of a variable ballast is to counteract the tipping moment created when a crane lifts a load. Unlike fixed counterweights, these adjustable counterweight systems allow operators to modify their balance in real-time. By adjusting the counterweight, crane operators can ensure that the center of gravity stays within safe limits, regardless of the load's position or weight.

Variable ballasts use metal blocks or some other type of stackable weight to keep cranes balanced. These weights can be adjusted, typically with removable pins or some other fastener, to match the specific requirements of each lift. This adaptability enables cranes to maintain optimal stability and performance across a wide range of load weights and distances.

 

A crane with a ballast wagon.

Types of Variable Ballasts

Ballast Tray/Suspended Ballast

Ballast trays, such as the VarioTray Ballast System® by Liebherr, feature a suspended platform that hangs behind the crane to provide balance. The weight of these ballasts can be adjusted as necessary and must be raised off the ground to swing or move the crane.

Benefits of Ballast Trays:

  • Allows for modular addition or removal of counterweights.
  • Can require less site preparation.
  • Can be used with various types and sizes of counterweight blocks.

Ballast Wagons

Ballast wagons are wheeled carts used to carry weight for derrick configurations. These attachments are positioned behind the crane and have different names depending on the manufacturer, such as Manitowoc's MAX-ER and Variable Positions Counterweight® (VPC®).

Benefits of Ballast Wagons:

  • Allows the crane to turn around and move without detaching the ballast wagon.
  • Some models can move counterweights inward as the crane swings, keeping a clearer swing path and eliminating obstructions for vehicle traffic.
  • Enables the crane to operate with varying counterweight configurations without lengthy setup times. 

Extendable Ballasts

Extendable ballasts use adjustable weights to change the ballast radius to accommodate different lifting requirements. For example, Liebherr’s VarioBallast® uses a mechanically slewing ballasting cylinders that can extend from a crane’s superstructure for higher lifting capacities.

Benefits of Extendable Ballasts:

  • Can significantly improve lift capacity.
  • Allows the crane to turn around and move without detaching the ballast wagon.

Variable Position Counterweights

Manitowoc’s Variable Position Counterweight (VPC) and VPC-MAX is a self-adjusting counterweight system used to evenly distribute the ground bearing load for cranes. This adjustable tray detects changes in boom angle to automatically adjust the counterweight by moving along the crane’s superstructure.

Benefits of Variable Position Counterweights:

  • Offers automated adjustment capabilities during lifting operations.
  • Provides precise counterbalance adjustments without changing the total counterweight.
  • Allows for more compact transportation configurations when the counterweight is retracted.
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When you need reliable lifting solutions, ALL Crane can help you invest in the best, most cost-effective variable ballast solution for your business. As the largest privately-owned crane rental and sales enterprise in North America, we offer a wide variety of cranes equipped with state-of-the-art variable ballast systems. Work with ALL today to invest in the right heavy lifting solution for your jobs.

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