Project Summary
Client: Form 700
Location: Warrnambool, Victoria
Crane: Liebherr LTM 1250-5.1
Project Overview
Premier Cranes & Rigging was engaged to support the installation of two tower cranes for the Warrnambool Base Hospital redevelopment.
The scope involved assembling and installing the tower sections, machine decks and long jib sections for both cranes using the Liebherr LTM 1250-5.1.
The first tower crane included a 20-tonne machine deck and a 64.2-metre jib, while the second included a 16-tonne machine deck and a 59.6-metre jib.
Each component required its own crane configuration, rigging arrangement and operating radius.
Challenges
Installing Two Tower Cranes Across an Active Construction Site
The two tower cranes were positioned in separate areas of the hospital site, requiring two carefully planned mobile crane setups.
The lift zones were surrounded by crane foundations, structural works and designated loading bays. The mobile crane needed to be positioned accurately so each component could be collected from the loading area and installed without interfering with surrounding works.
Long Jib Sections
The most demanding components were the:
- 64.2-metre jib for TC1
- 59.6-metre jib for TC2
Their length introduced additional considerations around load control, lifting height, wind conditions and clear communication between the crane operator and rigging crew.
The elevation studies showed the jibs being installed at radii of 24 and 26 metres, requiring careful coordination throughout the lift path.
Different Loads and Lift Radii
The installation included components ranging from 9 to 20 tonnes, with operating radii between 17 and 26 metres.
The highest planned crane utilisation occurred during the installation of the TC1 jib, where the LTM 1250-5.1 operated at approximately 89% utilisation.
This made accurate setup and strict adherence to the engineered lift plan essential.
The Solution
Liebherr LTM 1250-5.1
The LTM 1250-5.1was configured with 68 tonnes of counterweight and full outriggers to provide the reach, capacity and stability required across both tower crane installations.
Its configuration was adjusted between lifts, using boom lengths of approximately 51.9 metres for the tower sections and machine decks, and 59.3 metres for the longer jib installations.
Lift-Specific Rigging
Each tower crane component required a dedicated rigging arrangement. Grade 100 chains were used for the tower sections and machine decks, while the long jib sections also incorporated round slings to support the load and maintain control throughout the lift.
This ensured every component remained balanced and protected while being positioned onto the tower structure.
Ground Load Management
The crane was supported on 2.4 x 2.4-metre steel bog mats to spread the outrigger loads across the working area.
Ground bearing pressures were assessed for each lift configuration, with the highest planned pressure reaching approximately 130 kPa during the installation of the TC1 machine deck.
Sequenced Installation
The operation was planned in a clear sequence:
- Install the tower sections.
- Position the machine deck.
- Install the A-frame and supporting components.
- Lift and connect the full jib section.
This approach allowed the crew to build each tower crane progressively while maintaining control of the site and preparing safely for the next lift.
CONCLUSION
Controlled Planning Across Every Stage
The planned installation brought together multiple lift configurations, long structural components and two separate tower crane locations within one active hospital redevelopment site.
Through detailed lift studies, controlled sequencing and close coordination with the client and site teams, Premier developed a practical lifting solution for each stage of the installation.
The project reflects what successful tower crane assembly relies on: accurate crane positioning, the right rigging, disciplined communication and a clear plan before the first component leaves the ground.
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