Gerber Engineering

Gerber Engineering

About us Gerber Engineering is an analysis and consulting company that can help you with the design of your heavy construction equipment and machinery. We serve some of the leading businesses in the lifting and construction equipment sectors by helping them with new product development, structural analysis and optimization, capacity prediction, and concept creation. Kyle Gerber P.E.
Owner and Principle Analyst
Kyle grew up in the foothills of Wyoming below the Wind River mountain range. He attended Cedarville University on a baseball scholarship and graduated with a degree in Mechanical Engineering. After college, Kyle went to work in the construction sector and has spent nearly 15 years designing mobile hydraulic equipment. He has held engineering positions such as Design Engineer, Project Engineer, Senior Structural Engineer, Chief Engineer, and Division Manager. Kyle has worked for some of the largest multi-national construction equipment companies such as Terex, Time Mfg, and Sany. Kyle’s primary area of expertise is in the field of structural analysis and design. From 2012 – 2015 Kyle and his family served as expatriates in Huzhou, ZheJiang, China. In this capacity, his role was to communicate the design functionality and quality requirements for the equipment to compete in the mature markets of North America and Europe. Also during this time, Kyle introduced a new design utilizing synthetic fiber rope in the extension system of a telescopic crane boom.
Engineering Experience
Sany America Peachtree City, GA

110 Ton Telescopic Crawler Crane New Model

  • Design of 5 Section boom
    • Implementation of Synthetic Fiber Rope in extend and retract system of boom
      • Selected the sizes of the ropes as well as the type of fiber to be used in the construction of the ropes
      • Worked with European fiber manufacturer and Asian rope manufacturer to conduct necessary testing to insure rope was suitable for application inside boom
        • Cyclic bend testing around sheave with same diameter as used in the boom
        • Tensile testing
        • Testing of shortened end splice due to space constraints inside boom
    • Managed cycle testing of boom on machine. To insure rope could withstand at 15 years of normal operation the boom was cycled as various lengths, angles, loads, and lateral inclinations.
    • Tested the creep resistance of the material under high heat and high load conditions
    • Implementation of unique section shape
      • Maintained same resistance to local buckling as previous design
      • Reduced manufacturing time
      • Obtained larger vertical and lateral moments of inertia for increased bending stiffness
    • Patent pending design for arrangement of sheaves in extend mechanism
    • Created new design for retract rope anchor to allow for easy adjustment
    • Created new design for internal wear pads to allow for easy adjustment
    • Integrated counterbalance valve into rod of extend cylinders to eliminate external valve block
    • Created hydraulic boom assembly stands to allow for easy insertion of one boom sections into another during boom assembly

Load chart capacity prediction program for Telescopic Crawler cranes

  • Created two computer programs, one to calculate the structural capacity of the boom, and the other to calculate the structural capacity of the crane as a whole
  • Boom program calculated the capacity of the boom based on the structural capacity of the following components.
    • Boom section tubes
    • Extend cylinder pressure and buckling strength
    • Extend rope strength
    • Jib structural capacity
  • Designed boom program to effectively calculate the deflection of the boom for any point in the load chart
  • Load chart program calculated a machine load chart based on structural capacities of the following components
    • Boom structures
    • Hoist cylinder
    • Car body and crawler frames
    • Machine stability
    • Machine lateral inclination
  • Designed functionality into the program to perform ‘batch’ runs. This enabled the program to calculate hundreds of loads charts from a user defined input file.
  • Program was used to create entire set of load charts for 110 Ton Telescopic Crawler Crane

80 Ton Rough Terrain Crane New Model

  • Design of Superstructure
    • Design of rotating bed weldment
      • Weight reduction of 15% over previous model
      • Reduced number of unique materials used by 50%
    • Design of integrated winces in rotating bed
      • Designed rotating bed to accept name brand supplier winch drum and motor
      • Designed custom winch tensioner
    • Design of counterweight removal system
      • Counterweight removal system was scalable to be used on 80 Ton – 150 Ton RT cranes by adding or removing counterweight plates
      • Removal or installation could be performed entirely from the CAB
    • Design of swing lock
      • Lock could be engaged/disengaged from inside the cab
      • Handle mechanism connected to push/pull cable with integrated spring allowed for easy engagement even when teeth of lock were not perfectly aligned with teeth in swing gear

Time Manuracturing Waco, TX

210 Foot Electrically Insulated Aerial Lift

  • Refresh design of boom tube weldments to increase manufacturability
  • Design of sheet metal covers and boxes
  • Troubleshoot design issues with hose track
  • Troubleshoot electrical and hydraulic issues

Terex Cranes Wavery, IA

35 Ton Boom Truck New Model

  • Design of 3 section boom
    • Sizing of boom section tubes. This includes plate thickness and material selection.
    • Extend cylinder sizing
    • Extend and retract rope selection and sizing
    • Boom assembly eight reduction of 600 lbs
    • Improved lifting capacity of up to 20%
    • Reduction in assembly time of 3 hours
  • Design of jib
    • Jib base section and pull-out section tube sizing
    • Design of roller mechanism for easy extraction of pull-out section
    • Design of jib stowage brackets
    • Weight reduction of 100 lbs
  • Design of Turret weldment
    • Turret plate sizing and structural analysis
    • Used only two materials to increase nesting efficiency and reduce drop
    • Increased hoist cylinder geometry for better low angle performance
    • Weight reduction of 400 lbs
  • Design of swing bearing
    • Created commonality between three different models by using different combinations of bolt holes for each model
    • Implemented “bottom tapped” holes for easier assembly
    • Reduced fastener size for easier torqueing of bolts
    • Weight reduction of 40 lbs
  • SAE structural and stability testing
    • Prepared test plans to satisfy SAE requirements for both structural and stability testing
    • Identified locations for strain gages on turret, boom, and jib
    • Identified locations for brittle lacquer on turret, boom, and jib
    • Managed structural testing performed by 3rd party and stability performed by manufacturer

130 Ton Rough Terrain Crane New Model

  • Design of 5 Section boom
    • Implementation of new section shape for improved plate buckling characteristics
    • Sizing of boom section tubes. This includes plate thickness and material selection.
    • Sizing and selection of extend and retract chains
    • Design and sizing of both extend cylinders
    • Cost reduction of 40% over previous model
  • SAE structural and stability testing
    • Prepared test plans to satisfy SAE requirements for both structural and stability testing
    • Identified locations for strain gages on boom based on FEA analysis
    • Managed structural and stability testing performed by manufacturer

Load chart capacity prediction program for Rough Terrain cranes

  • Created two computer programs, one to calculate the structural capacity of the boom, and the other to calculate the structural capacity of the crane as a whole
  • Boom program calculated capacity of the boom based on boom angle and section overlap at specific boom lengths
  • Effects of localized plate buckling was considered in boom capacity calculations
  • Load chart program created a machine load chart based on structural capacities of the following
    • Boom structures
    • Hoist cylinder
    • Outriggers
    • Machine stability
  • Program was used to create entire set of load charts for 130 Ton machine
Professional Services

Machine and Structural Design We have experience designing steel structures of all kinds. We can handle anything from static structural components, to mechanical linkages, to large complex assemblies.


Structural Analysis Structural analysis is our core competency. We can perform classical stress and displacement calculations as well as Finite Element Analysis (FEA) on complicated structures. If required, our licensed Professional Engineer will stamp your drawings to provide compliance with state and federal regulations.


2D Drafting and Detailing We have the capability to provide complete 2D drawings sets of your design. We can follow the ASME Y14 standards as well as any internal drafting standard you may have.


Calculation Tool Development Along with structural design and analysis, we also have the capability to develop custom calculation tools for your own internal Engineering use. This can be anything from multi-thousand line VBA programs to simple spreadsheet calculators.

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