Tutt Bryant Heavy Lift & Shift (TBHLS) completed a complex turnkey installation of concrete bridge beams ahead of schedule.
In August 2022, TBHLS completed the lifts on the Tonkin Gap Project and Associated Works for Broun Ave Stage 2, for the Tonkin Gap Alliance in Perth, Western Australia.
Project mobilisation started August 15 and the lifts occurred over a two day period with demobilisation starting on August 29.
As a result of meticulous planning and open communication, the project finished 16 hours ahead of schedule.
The turnkey lifting service involved the installation of 18 x 188t, 39m long concrete bridge beams over the Tonkin Highway on both the northbound and southbound carriageways.
This bridge installation was part of the Main Roads WA Tonkin Gap Project and Associated Works to provide four traffic lanes and an integrated bus interchange linking to the future Morley Station on the median strip of Tonkin Highway.
Tutt Bryant Heavy Lift & Shift (TBHLS) proposed to use the Manitowoc MLC650 700t crawler crane in 68mB VPC MAX S3 configuration and carried out the bridge span installations whilst positioned on the median strip of north and south bound traffic on Tonkin Highway.
The main reason for the suggestion of the MLC650 crawler is the small footprint (12m x 12m) compared to a conventional super-lift crawler crane.
The combination of having the crane’s counterweights always suspended and ability for the counterweights to travel autonomously served as the biggest financial savings in less earthworks, less build time, reduces the time and labour spent on relocating counterweights between lifts.
TBHLS engaged its JV partner Cranecorp Australia to provide a 300t all-terrain mobile crane Demag AC300-6 for the assembly of the crane.
A total of 43 trailers over a six day period were used to move the crane to site.
The team was a day over the proposed schedule due to Perth metro curfews limiting oversized loads (greater than 3m width) to be delivered to the site prior to the 9:00am peak hour traffic, and on-going earthworks onsite for the crane pads.
TBHLS utilised its own rigging spreader and sourced the remaining rigging gear from local suppliers located within Perth metro region.
METHODOLOGY & CHALLENGES
The 700t crawler was to be mobilised in 68 square metre VPC MAX S3 configuration and built within the median strip between north and south bound traffic that remained live up to installation window on August 26 2022.
The biggest challenge was to build the crane within a 20m wide work area whilst maintaining a 4m boundary to provide accessway for general site traffic, construction of the crane pad and crane component delivery.
The crane was configured and positioned in two locations for the whole bridge assembly. This configuration allowed for the delivery beams from the lay down area to either side of the crane, creating multiple options on transport flow when the road was closed.
It also allowed greater access for the installation team to position access equipment to assist with aligning the bridge beams in their final locations.
TBHLS and the Tonkin Gap Alliance (TGA) engineering team had extensive discussions around ground pressure requirements, clearance restrictions and underground service locations that needed to be avoided or maintained during all stages of the crane build to bridge beam installation.
The team worked to the maximum allowable GBP of 800kPa which was achievable while using the crane to 85 per cent of its lifting capacity. TGA designed, constructed and tested the crane pad to allow the crane to travel and lift without the use of load spreading crane mats.
A good relationship between TGA and TBHLS was a vital part towards the success for this project with numerous meetings held between all major stakeholders. The TBHLS project team helped to develop a successful proposal that was well executed.
A total of 60 hours (5 x 12 hour work shifts running both day and night shifts) were allocated for this installation. Starting on Friday night, despite the tight clearances and cold winter conditions, the team successfully completed the installation of all 18 bridge beams within 44 hours (3.6 shifts) – 16 hours ahead of schedule.
Excellent planning and open communication throughout all phases of the project between TBHLS and TGA project team ensured that there was no problems or challenges that could not be solved. An excellent showcase of teamwork and Tutt Bryant’s capability to provide turnkey lifting solutions.