From the construction of facilities to managing everyday operations, mine and construction sites frequently need to handle extremely heavy and dangerous loads. One of the most efficient methods to relocate large and heavy structures and modules is through the use of cranes. However, this can be both complex and dangerous and it is therefore imperative that the people and companies that are involved in heavy lifting have the appropriate knowledge and experience to do so.
In 2018, WA construction giant Civmec commissioned Heavy Lift Designs (HLD) to plan the lifting of high-value and critical components and modules at Alcoa of Australia Ltd’s (Alcoa) Pinjarra Alumina Refinery, located some 80 kilometres south of Perth in Western Australia.
A key part of HLD’s works included the preparation of high level, comprehensive lift plans and methodologies for the lifting of one of the largest single piece switchrooms in Australia, which was being transported directly by road to its final position at Alcoa’s filtration plant.
At 37.3 metres long, 5.6 metres wide, 4.5 metres high and weighing just over 100 tonnes, the lifting of the unit presented complex challenges as it was vital that the module was not subject to twisting or bending during the lifting process.
HLD WA Manager Russell Parker said another very important part of the project brief was that HLD had to ensure that all lifting activities were carried out in the safest and most efficient way possible.
“Safety was by far the highest priority and Civmec proved to be fully on board with all of our recommendations in that regard,” said Mr Parker. “Apart from needing to comply with our client’s project requirements, we also had to ensure we met the very high standards of Alcoa, in terms of lifting procedures and safety. This also involved some liaison with vendors in regard to the best methods for lifting of complex machinery and components,” he said. To deliver on the brief, each stage of the lifting operation was carefully detailed prior to work commencing.
HLD’s lifting planning process involves the use of several software packages such as AutoCAD, NavisWorks, Inventor and OEM crane manufacturer software packages. HLD combines these with on-the-ground heavy lifting experience, mechanical engineering and close liaison with clients to ensure the company meets clients’ expectations. This was especially important with the lifting of the switchroom at Pinjarra.
“We first discuss internally how we best approach the planning, then start work on preliminary designs for the client’s consideration,” explained HLD Managing Director, Blake Hammon, “we then go through a process of consultation and review with our client, to ensure we produce a final lift plan that meets every one of the client’s requirements.”
An important part of the planning process was to use readily available ‘off the shelf’ rigging equipment to keep costs down where possible and avoid any delays in having to source non-standard rigging gear. In the end this was achieved, and all the required rigging was on site well before the delivery of the switchroom.
On the day of the lift, a pre-lift meeting was held by the crane crew and supervision, to go through the methodology and lift plan provided by HLD to ensure all involved personnel were aware of their various roles and responsibilities. The Civmec crane crew then ensured both the crane and switchroom were in the correct positions as per the lift plan, before commencing to connect the rigging. Once connected, some initial weight was taken by the crane to check correct seating and alignment of the rigging connections. Once satisfied with the rigging, the lift was then carried out. The crane movements, including the handling of the Superlift counterweight tray, were carried out as per the HLD lift plan. The switchroom was lifted from the transport, slewed through 180 degrees, and landed on to its supports without any difficulty or delays.
During the lifting process, HLD employed the use of drones to facilitate and document an eagle-eye view of the cutting-edge design and lifting techniques for all to see. This drone utilisation allows further inspection of the designs in operation and is a new service that can be offered to clients.
Mr Parker said lifting the unit involved a lot of work between HLD, the client, the rigging equipment supplier and the vendor, to ensure the switchroom was correctly elevated.
“As an extremely high value and schedule critical component it was vital to them that the switchroom was lifted and installed on time, without damage, and in the safest way possible. We are proud to have helped Civmec achieve that goal on time and without incident.”
ABOUT HEAVY LIFT DESIGNS
Established in 2014, Heavy Lift Designs (HLD) is a specialist engineering company which has over 30 years’ experience in the planning of safe and cost-effective mobilisation, operation and demobilisation of a wide variety of crane types.
HLD provides a broad range of services for the Australian mining and minerals industry including lift studies, tower crane engineering, third party verification, feasibility studies, rigging diagrams/design and project management.
HLD is changing the heavy lifting industry by using the optimal combination of proven methodology with current technology. This, coupled with the fact that HLD is fully independent of any crane supplier, puts the company in a unique position of being able to provide honest and unbiased advice to a range of clients in the heavy lift field.
The company has been involved in several notable resources projects including assisting with planning major lifts for the Gorgon LNG plant’s first major shutdown and providing all heavy lift studies for RCR at Cloudbreak and Pilgangoora Lithium, but its most recent stand-out role was in its works for Civmec at Alcoa’s Pinjarra Alumina Refinery.