Lifting innovation wins CICA Award

-As featured in Cranes and Lifting Magazine, January 2020

A new lifting innovation designed for the Metro Tunnel Project and jointly developed by John Holland, Edwards Heavy Lift and RUD won the 2019 CICA Innovations Award.

John Holland, as a member of CYP Design & Construction Joint Venture (CYP D&C), is delivering the Tunnels and Stations works package of this landmark project, which includes new twin 9km rail tunnels and five new underground stations. The CYP D&C lifting device innovation was initially developed for works at the new North Melbourne Station site.

The innovative solution was developed to meet CYP D&C construction requirements at the site to safely and efficiently install propping steel, or struts, inside the station box.

Although designed for works at the station, the application of the innovation has expanded to other sites and uses.

There were a number of challenges. At the site of the new North Melbourne Station, ground improvements were required to support the use of crawler cranes required at the base of the station box to position struts into place lowered by surface-based cranes.

John Holland’s inhouse Lift & Shift team, part of the Technology Engineering & Knowledge (TEK) group, developed Australian-first tailored installation innovations by working closely with Edwards Heavy Lift and RUD as industry partners, and project teams.

C-hook background

John Holland Lift & Shift team member Duke Barac was asked by the North Melbourne Station project team to consider installation options for 5000 tonnes of propping steel, or struts, including a variety of length, the presence of Coode Island Silt in the station box and the need to install the struts at different angles.

Duke Barac considered the conditions and requirement to devise a solution to “flip” an over-sized spreader bar into a vertical configuration, which could both lower and place the struts into position by only using a surface-based crane. While the c-shape is used for smaller, specialised applications (e.g. forklift use), the nine-metre length of the C-hook and its vertical use is unique in Australia.

Two C-hook options were developed for the project’s consideration and these included a rigid C-hook – although cheaper to manufacture, its use would be restricted to only when a C-hook was required. The second design incorporated existing spreader bar and lifting beams components, which could be separated when the C-hook was not in use.

Edwards Heavy Lift was engaged to develop the detailed design and fabrication drawings for the C-hook using the concept design developed by Barac. RUD provided third-party design verification and manufactured the two C-hooks procured for the CYP D&C project.

C-hook features

Option two was selected due to the design’s interoperability features, which enables the dual-purpose hardware components to make-up conventional spreader bars and lifting beams when the C-hook is not required. Although using thicker wall sections, the spreader bar components were modular with existing spreaders and could be added to John Holland’s rigging inventory to optimise the additional investment.

C-hook benefits

Negating the need for crawler cranes and crews to work from the station box floor provided significant benefits including program time saving by avoiding the need for ground improvement works to support the crawler cranes as well as significant cost benefits.

The C-hook has successfully installed 4000 tonnes (of a total of 5000 tonnes) propping steel at the site of the new North Melbourne Station and has since been configured for use in other lifting work at the site, e.g. to manoeuvre lifts in areas of tight angles and restricted access.

C-hook planning & control measures

The C-hook was conceived early after understanding the requirements. 3D CAD models were developed, which were tested with project personnel as part of ongoing engagement in the development of the final solution

Desktop checks were undertaken, and the model was shared with the project’s Temporary Works team to assess for clashes.

Following these steps, Edwards Heavy Lift developed the detail design, Finite Element Analysis (FEA) modelling and fabrication drawings. RUD provided third-party design verification, including FEA.

The design used existing, proven components and as a new solution for installing struts, John Holland developed a training program.

The benefits of the innovation include safe and injury-free use of the C-hook.

Program efficiency was increased by eliminating the need for ground improvement works.

Major cost savings were realised. Use of the C-hook avoided the need for crawler cranes and work crews to install propping and avoiding the use of crawler cranes negated the need for ground improvements in the station box to provide weight-bearing conditions.

John Holland has enhanced the capability of its own people and subcontractors in using the new solutions, which they can take to other worksites and projects. The design of the C-hook incorporates dual-purpose components, so that when a C-hook is not required, its parts can be used in conventional rigging.

The design also uses existing hardware, e.g. the pins are from the same shackles used in spreader bars.

With the strong pipeline of future rail tunnels, John Holland – and the wider industry –has expanded options to draw on to deliver this work.

The innovation reflects John Holland’s values of Caring, Empowerment, Future-Focused and Imaginative, and will be used in an internal campaign to demonstrate the power of individuals to effect change.

THE C-hook was an untested, new solution unknown to John Holland’s own people and subcontractors, yet it has been embraced and its use expanded to new sites and applications.

C-Hook Lifting Innovation

C-Hook

Rud and John Holland - C-Hook Innovation

What Our Clients Say About RUD Australia

  • Patterson Mobile Crane Hire logo
    Laurie Patterson

    “Half the amount of gear for the same result”

    Patterson Crane Hire loves a challenge and RUD lifting gear helps us solve these challenges. The weight saving gains when we use their Grade 120 ICE range really makes a difference and minimises our risk when we are managing difficult, heavy lifts. Simply put, this is why we choose to work with quality suppliers like RUD.

  • Graeme Jones
    Operations Manager, Holcim Werribee

    “Safety and expertise a key factor for Holcim”

    At Holcim (Werribee) we rely on RUD Tyre Protection Chains. Their strong expertise and professionalism is on display when they fit and maintain our chains on site. The team works hard to keep us safe, enable our machines to stay in operation and minimise our costs.

  • air & allied sales logo
    Marcus Ghikas
    Managing Director, Air and Allied

    “Quality suppliers and supportive business partners, recommended without hesitation”

    Air & Allied Sales (Pacific) has partnered with RUD Chains for the past 25 years to deliver outstanding engineered solutions. The professional and continued relationship with Ian and his team allows us to continue to support our customers above and beyond their needs.

    Our recent requirements have pushed the limits of a standard supplier’s capabilities, but RUD Chains have never waivered in their scaled supply. As a result, we have been able to meet surges in demand without issue, passing on the excellent support offered by RUD Chains to our own customers.

    RUD Chains are both quality suppliers and supportive business partners, and we would recommend them without hesitation.

  • acran logo
    Richard Devereux, Managing Director
    ACRAN

    “RUD Chain Drives provide a controlled drive solution for engineering challenge.”

    As Managing Director of ACRAN, we are always excited to provide innovative and quality technical solutions to the market for industrial ventilation, filtration and noise control solutions.

    Recently we completed a project where RUD chain drives provided a controlled drive solution for an Engineered lift and fulfilled the requirements. ACRAN is grateful for the technical and on-site support provided by RUD Chains and look forward to completing future projects together as a trusted partner.

  • gemilang australia logo
    Sarah Forbes
    Gemilang

    “Australian Made Endurequip Hoists provide a safe and reliable maintenance system to deliver new bus fleets.”

    At Gemilang, we’re confident that our high-quality Endurequip-made Portalifts and vehicle stands will continue to serve us well as we build more buses for the Australian market. These provide us unparalleled underbody access, thereby giving our clients the reassurance that every single bus component, from top to bottom, is designed, manufactured, secured and inspected thoroughly by our engineers and technicians.

  • Aurizon logo
    Gavin Witton
    Project Leader, CQCN North Wagon Operations, Aurizon

    “Service Levels from design through to commissioning unmatched by others”

    The team at Jilalan appreciate the quality service you provided in the design, fabrication and commissioning of our platforms for our Wagon remediation project.

    RUD’s attention to detail and great communications skills ensured that our project was completed to the highest standard and exceeded our expectations.  From the start of the procurement process you committed to ensuring time frames could be met and delivered quality products as per agreement. We are grateful for this as no other company we contacted could make these commitments.

  • Grima recycling
    Jim Grima
    Grima Recycling

    “RUD service compliments RUD system quality”

    Grima Recycling have been working the team at RUD in realising our plant expansion project. The modular RUD chain conveyor has proved to be reliable and effective for the transfer of of our recycled products from the loader hopper and up the inclined slop as part of our new process line. The regular contact and support provided by RUD compliments the RUD system quality. 

  • Enco precast
    Forbes Day, Operations Manager
    Enco Precast Pty Ltd

    “RUD Engineering support and expertise a real asset”

    ENCO Precast have been involved with RUD for over 10 years now, predominantly for the supply of the Philipp Group Lifting Hoops for Prestressed Precast Concrete elements for bridges. The engineering support led by RUD’s Engineering Manager Matt Pauli is always outstanding and has kept us loyal to RUD.

  • The Jundee Nickel Mine
    Western Australia

    “RUD Toro X19 chains have surpassed all of our expectations”

    RUD’s service and product support have been excellent. We are happy to recommend RUD to anyone who has problems with their tyre life.

  • bullivants logo
    Paul Denison
    Bullivants Townsville

    “The RUD team were able to design, manufacture and supply a cost effective solution”

    We see our long term relationship with RUD more as a partnership than supplier and customer. RUD’s service and product support are excellent and their team of industry specialists is always on hand to answer any of our questions.

Talk to RUD today to find out more about our solutions.