Project Summary
Location: Melbourne
Crane: Liebherr LTM1250-5.1
Project Overview
At Premier, we pride ourselves on partnering with clients to find innovative solutions to complex lifting challenges.
For this project, we were entrusted with the critical task of delivering and positioning a two-storey-high backup generator system (94.1 tonnes in total) into the one remaining bay at a critical data facility – a bay located right at the centre of an array of existing generators.
The unit arrived late in the build, requiring installation into the centre of a live plant with zero tolerance for vibration or operational disruption.
The generator was divided into three major components, each requiring its own unique engineered lift path:
- 40.7-tonne bottom enclosure
- ~28-tonne attenuator
- ~21-tonne engine module
With centimetre-level clearances and a minimal crane footprint, traditional crane setups were impossible.
Following 12 months of planning and engineering, Premier safely delivered a lift many considered unachievable.
This project, proudly submitted as our entry for the CICA Lift of the Year over 20 tonnes, showcased the depth of our planning and technical capability, going on to win the category at this year's CICA National Awards.
CHALLENGES:
This lift was delivered inside a live, high-security data centre where the operational environment imposed significant constraints on crane selection, access and allowable movement.
The only access into the generator compound was via a single 5.6-metre-wide driveway flanked by buildings and existing generator units, immediately ruling out larger cranes, dual-lift methodologies and all alternative delivery methods.
Traditional crane setup geometry was impossible, requiring the LTM1250-5.1 to be manoeuvred into position with millimetre-level precision.
The team had to configure asymmetrical outriggers to fit the crane into the narrow corridor, while reducing the counterweight radius to avoid structural clashes during slewing.
Even with these innovations, the operator worked within a highly restricted slew arc, achieving clearances as tight as 15 millimetres between the counterweight and an onsite water tank and the operator’s cab and an adjacent generator.
Beyond the physical constraints, the lift was executed in the centre of a fully operational data centre, meaning no interruptions to critical infrastructure were permissible.
SOLUTIONS:
To address the extreme spatial constraints and live-site sensitivities, the team delivered a tailored lifting strategy built around the capabilities of the Liebherr LTM1250-5.1. Every element of the solution was engineered to fit the environment, not the other way around.
Key components of the solution included:
- Customised Crane Configuration
- Utilised VarioBase to asymmetrically extend outriggers and establish a safe support polygon inside the 5.6-metre access lane.
- Employed VarioBallast to reduce the counterweight radius, enabling safe slewing between buildings without structural clashes.
- Selected the strongest boom configuration to maintain lifting capacity while preserving overhead clearances.
- Precision Engineering and Lift Planning
- Conducted 3D modelling and swept-path analysis to validate every crane movement, from mobilisation to final placement.
- Completed detailed load, rigging and tension calculations to safely manage:
- Offset centre of gravity
- Narrow load paths
- Millimetre-level clearances
- Designed lightweight, high-strength rigging solutions to maximise crane capacity within the tight geometry.
- Staged Delivery and Sequenced Logistics
- Coordinated over-dimensional transport, assist cranes and the LTM1250-5.1 through a single one-way access road.
- Managed deliveries in a strict order to avoid congestion and maintain continuous access for data centre operations.
- Used the 60t assist crane to assemble and later strip the 1250’s counterweights, reducing setup time in the constrained footprint.
- Live-Site Operational Controls
- Implemented strict communication protocols, with dedicated spotters monitoring counterweight clearance, slew limits and overhead obstructions.
- Leveraged LICCON monitoring to ensure crane utilisation and outrigger reactions stayed within safe tolerances at all times.
- Controlled noise, vibration and environmental impacts to protect sensitive data centre infrastructure.
OUTCOME:
This integrated approach allowed the team to safely execute a complex, high-stakes lift within millimetres of live infrastructure, demonstrating the strength of planning, engineering rigour and #TeamLifting collaboration.
CONCLUSION
Throughout the project, safety remained our guiding principle. By combining thorough planning, real-time vigilance, and contingency readiness, we achieved a complex lift in a live environment with zero incidents.
Through engineered planning, modern crane capability and disciplined execution, the 94t generator was placed safely at the heart of the facility.
Our team is proud that we met the challenge with an unwavering commitment to safety at every turn. #TeamLifting
Need engineered lifting solutions for restricted or live environments?
Call (03) 9311 1499 or book your lift at premiercranes.com.au.