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Versa Cranes and the Rise of Custom Heavy Lift Solutions
Versa Cranes, a division of the Houston-based Versa Companies, specializes in custom-engineered lifting equipment for extreme applications. Unlike mass-produced crawler cranes or tower cranes, Versa’s machines are often one-of-a-kind builds tailored for specific infrastructure projects. The Versa 9600 is a prime example—a purpose-built crane designed to lift ultra-heavy components like bridge girders, refinery vessels, and precast concrete segments.
Versa began operations in the late 1990s, focusing on modular transport and engineered rigging. Their cranes are known for combining hydraulic boom systems with high-capacity winches and custom counterweight configurations. While exact production numbers are limited, the Versa 9600 is believed to be one of only a handful of units ever assembled, making it a rare sight even in major construction hubs.
Midnight Lifts in Dallas with the Versa 9600
In the summer of 2010, the Versa 9600 was deployed in the Dallas–Fort Worth metroplex to lift eight massive concrete bridge girders, each measuring 160 feet in length and weighing 240 tons. The lifts were scheduled overnight to minimize traffic disruption and maximize safety. Each girder required approximately four hours to rig, hoist, and set into place.
The crane’s performance was notable not just for its capacity, but for its precision. Operating in tight urban corridors with limited swing clearance, the Versa 9600 demonstrated exceptional control thanks to its hydrostatic boom articulation and multi-point load monitoring system.
Lift parameters included:
Technical Features of the Versa 9600
The Versa 9600 is not a conventional crane. It blends elements of hydraulic truck cranes, gantry systems, and engineered lift frames. Its modular design allows it to be transported in sections and assembled on site.
Key features include:
Challenges in Ultra-Heavy Lifting
Lifting 240-ton girders is not just a matter of brute force. Engineers must account for:
Versa’s Role in Infrastructure Expansion
As urban infrastructure grows more complex, cranes like the Versa 9600 are becoming essential. Traditional crawler cranes may lack the reach or capacity for modern bridge segments, especially those built with precast post-tensioned concrete. Versa’s ability to engineer custom lifting solutions has made it a go-to partner for DOTs and major contractors.
Recent deployments include:
Conclusion
The Versa 9600’s performance in Dallas was more than a technical feat—it was a showcase of what modern engineered lifting can achieve. With its unique design, massive capacity, and precision controls, the crane successfully placed eight 240-ton girders under challenging conditions. As infrastructure demands continue to rise, machines like the Versa 9600 will play a critical role in shaping the skylines and roadways of tomorrow. For those lucky enough to witness it in action, it was a night to remember—and a reminder of the power behind precision.
Versa Cranes, a division of the Houston-based Versa Companies, specializes in custom-engineered lifting equipment for extreme applications. Unlike mass-produced crawler cranes or tower cranes, Versa’s machines are often one-of-a-kind builds tailored for specific infrastructure projects. The Versa 9600 is a prime example—a purpose-built crane designed to lift ultra-heavy components like bridge girders, refinery vessels, and precast concrete segments.
Versa began operations in the late 1990s, focusing on modular transport and engineered rigging. Their cranes are known for combining hydraulic boom systems with high-capacity winches and custom counterweight configurations. While exact production numbers are limited, the Versa 9600 is believed to be one of only a handful of units ever assembled, making it a rare sight even in major construction hubs.
Midnight Lifts in Dallas with the Versa 9600
In the summer of 2010, the Versa 9600 was deployed in the Dallas–Fort Worth metroplex to lift eight massive concrete bridge girders, each measuring 160 feet in length and weighing 240 tons. The lifts were scheduled overnight to minimize traffic disruption and maximize safety. Each girder required approximately four hours to rig, hoist, and set into place.
The crane’s performance was notable not just for its capacity, but for its precision. Operating in tight urban corridors with limited swing clearance, the Versa 9600 demonstrated exceptional control thanks to its hydrostatic boom articulation and multi-point load monitoring system.
Lift parameters included:
- Load weight: 240 tons per girder
- Length: 160 feet
- Lift duration: ~4 hours per girder
- Total girders: 8 over 4 nights
- Crew size: ~12 riggers and operators per shift
Technical Features of the Versa 9600
The Versa 9600 is not a conventional crane. It blends elements of hydraulic truck cranes, gantry systems, and engineered lift frames. Its modular design allows it to be transported in sections and assembled on site.
Key features include:
- Telescopic hydraulic boom with multi-stage extension
- Dual winch system for synchronized lifting
- Custom counterweight modules exceeding 100,000 lbs
- Load moment indicator with real-time feedback
- Remote control capability for precision positioning
- Reinforced outriggers with steel matting for ground pressure distribution
Challenges in Ultra-Heavy Lifting
Lifting 240-ton girders is not just a matter of brute force. Engineers must account for:
- Wind load and swing radius
- Ground bearing capacity
- Rigging geometry and center of gravity
- Boom deflection and dynamic load factors
- Coordination with transport vehicles and site crews
Versa’s Role in Infrastructure Expansion
As urban infrastructure grows more complex, cranes like the Versa 9600 are becoming essential. Traditional crawler cranes may lack the reach or capacity for modern bridge segments, especially those built with precast post-tensioned concrete. Versa’s ability to engineer custom lifting solutions has made it a go-to partner for DOTs and major contractors.
Recent deployments include:
- Refinery vessel lifts in Houston
- Wind turbine nacelle installations in West Texas
- Stadium roof truss placements in Florida
- Modular bridge segment lifts in California
Conclusion
The Versa 9600’s performance in Dallas was more than a technical feat—it was a showcase of what modern engineered lifting can achieve. With its unique design, massive capacity, and precision controls, the crane successfully placed eight 240-ton girders under challenging conditions. As infrastructure demands continue to rise, machines like the Versa 9600 will play a critical role in shaping the skylines and roadways of tomorrow. For those lucky enough to witness it in action, it was a night to remember—and a reminder of the power behind precision.
