Dual lift Precast Road Deck Inside the West Gate Tunnel

Dual lift Precast Road Deck Inside the West Gate Tunnel

Project Summary

Client: CPBJH JV

Location: West Gate Tunnel, North Portal

Crane: Liebherr LTM1120 4.1, Liebherr LTM1060 3.1

Project Overview

Dual lift Precast Road Deck Inside the West Gate Tunnel

At Premier Cranes & Rigging, we pride ourselves on partnering with clients to find innovative solutions to complex lifting challenges.

For this project, CPBJH JV entrusted us with the critical task of installing 176 precast road deck planks at the entry and exit points of the West Gate Tunnel.

The confined space within the tunnel presented considerable complexity, offering only 6.7 metres of headroom.

We knew that success would require a tailored plan—balancing advanced crane capabilities with careful load distribution to ensure smooth and safe operations.

This dual lift installation earned us the CICA Lift of the Year 2024 (Under 20t) People’s Choice Award, highlighting our ability to tackle complex challenges while embodying the spirit of #TeamLifting.

Challenge:
  • Limited Headroom: With just 6.7 metres of clearance from the plank level to the roof, operational space was restricted. Precision was essential to safely install each plank within these tight confines.
  • Maintaining Access: The tunnel’s driveway needed to remain open for vehicles throughout the project, meaning crane movements and plank installation had to be carefully coordinated.
  • Suspended Planks and Load Distribution: The cranes were set up on suspended slabs, meaning every load had to be distributed evenly to preserve the structural integrity of the driveway.
Solution:

We developed a dual-crane setup and tailored lifting strategy, working closely with CPBJH JV to overcome the project's challenges:

Dual-Crane Setup

  • Liebherr LTM1120 4.1: Configured on full outriggers, this crane operated at a 24-metre radius, offering the capacity to manage heavier loads efficiently.
  • Liebherr LTM1060 3.1: This crane was set up on 0% outriggers, operating with a 12-metre radius.

Both cranes were driven into the tunnel with counterweights in place, maximising efficiency and reducing setup time.

Custom Rigging Configuration

  • We applied a 120% dual lift safety factor to manage the 11.4-tonne planks safely.

Ekki Timber Runway and Steel Bog Mats

  • To maintain continuous access for vehicles, we built an ekki timber runway across the driveway under the LTM1060 3.1. This provided a stable operating surface for the cranes while allowing construction traffic to move through the site.
  • Used steel bog mats beneath three slabs for the LTM1120 4.1 to distribute the load evenly.
Outcome:

This dual lift was a resounding success, showcasing our ability to deliver on complex infrastructure challenges through innovative planning and seamless execution.

Our collaboration with CPBJH JV ensured the project remained on schedule, with all 176 planks installed efficiently and safely.

Our #TeamLifting spirit was key to the success of this project, enabling us to tackle the challenges of confined spaces and maintaining access without disruption to site operations.

At Premier Cranes & Rigging, we take pride in trying to find a way.

Whether it’s working on suspended slabs or operating in challenging conditions, we deliver results through expertise, teamwork, and meticulous planning.

If your project demands innovative lifting solutions, let’s talk—our team is ready to exceed your expectations.