Bridge and infrastructure maintenance technologies that can lift, shift and manoeuvre heavy structures to tolerances down to margins less than a millimetre are being introduced to Australasia by Enerpac to improve workplace safety and cost-efficiency when maintaining ageing structures.
The compact PLC controlled high-pressure (700 bar) hydraulic technologies – including synchronous lift, stage lift and crane assistance technologies – are suitable for public and private infrastructure projects ranging from major concrete and steel road and rail bridges through to the tens of thousands of smaller timber and concrete bridges maintained by local authorities. They also are used extensively in infrastructure construction and upgrading of road, rail and port facilities.
Engineered to reduce manpower, hazards and complexity on projects such as bearing replacement, deck lifting, de-propping and structural repair, the latest maintenance technologies complement Enerpac's bridge launching technologies, such as its globally unique spindle bar systems and Enerlauncher incremental launching systems used on high-precision projects such as main trunk routes and high viaducts.
Enerpac says the latest technologies available in Australia and New Zealand are evolved from products that have been proven in global landmark projects, such as lifting of the Golden Gate Bridge for maintenance and the construction of the Millau viaduct in France, which, with a mast summit of 343 metres, is twice as high as the Sydney Harbour Bridge.
"The benefits of such projects and technologies have spread across a whole range of tasks confronting Australia and New Zealand as they refurbish and renew their private and public and private main route and regional infrastructure. It is estimated* that there are more 30,000 timber and concrete bridges maintained by local authorities, for example, of which more than a quarter are in poor or fair condition," * says Enerpac Australasia Integrated Systems Manager Mr Warren Baltineshter. Enerpac Integrated Solutions' expertise dedicated to lifting, shifting and manoeuvring some of the world's most challenging objects and structures.
Source: National State of the Assets Survey 2015
Integrated Solutions for bridge maintenance
Enerpac bridge maintenance technologies such as the EVO Synchronous Lifting System, SFP-Series Split Flow Pumps, BLS-Series Stage Lift Cylinders, Strand Jack Systems, SyncHoist and Hydraulic Gantry systems are members the Enerpac Integrated Solutions family, which is backed globally by the expertise and experience of the Enerpac Integrated Solutions Team lead locally by Mr Baltineshter.
"Heavy lifts are a complex and specialised discipline where one technology does not fit all," he says.
"Sometimes the enormous power and precision of synchronous hydraulic technology is the best option for bridging and infrastructure; sometimes standard indoor and outdoor cranes can do the job cost-efficiently; and sometimes lifting gantries are a safe and cost-efficient option for tasks across industries such as mining and resources plant, oil and gas structures, energy and infrastructure installation and maintenance and ports and shipping tasks.
"All heavy infrastructure and plant lifts however share the need to complete the task not only with maximum cost-efficiency, but also with optimum safety and ease of control."
Enerpac Bridge Maintenance Technologies
EVO Synchronous Lifting System: Instead of teams of lifting personnel trying to manually co-ordinate lifts involving hydraulic cylinders often widely dispersed around a job, the EVO Series Synchronous Lifting System integrates control of all cylinders into a PLC system controlled by a single person. Through an integrated HMI (Human Machine Interface), all movements are managed from a central control position that displays live operation with real-time status updates for each lifting position.
The process does not have to be stopped after any incremental value, then checked, manually re-measured and corrected. The EVO-System carries out these actions during the entire lifting process, even with low lifting or lowering speeds. Depending on the application, time savings up to 60 percent can be achieved.
SFP-Series Split Flow Pumps: The SFP system is specifically designed to assist in safely and cost-efficiently lifting evenly distributed loads for the building and construction, mining, oil and gas and shipping industries. The SFP-Series electrically driven 700 bar split flow pumps are an ideal solution for lifting applications with lifting multiple points where lifting synchronisation of a maximum ±4% is appropriate to ensure safety of the job.
SFP-Series split flow pumps are particularly beneficial when lifting complex loads with multiple lift points, and are a far more efficient and safe option than using separately operated pumps, as they provide greater consistency of flow, says Enerpac. The load can be lifted simultaneously using single or double-acting cylinders. Depending on the application, the lifting points can be operated individually or simultaneously.
BLS-Series Hydraulic Stage Lifting Cylinders: Enerpac stage lift cylinders provide a simple method by which loads of 50-200 tons can be lifted many times the stroke of the cylinders involved. Total height is only limited by the strength and stability of the cribbing system.
Features of the BLS-Series include:
- Double-acting cylinder with solid plunger design
- Simple three-stage operation
- Swivel saddle and large support attachments for stability
- Anti-rotation device
- Built-in overload protection
Strand Jack Systems: In a strand jack, a bundle of steel cables or strands are guided through a hydraulic cylinder; above and below the cylinder are anchor systems with wedges that grip the strand bundle. By stroking the cylinder in and out while the grips are engaged in the anchors, a lifting or lowering movement is achieved.
The power and precision of stand jacking has been demonstrated in Australian resources and infrastructure projects, including lifts of 800-1400 ton ball mills. These unites were hoisted and positioned on their pedestals with an Enerpac PLC controlled lift system capable of safely positioning huge loads to accuracies within fractions of a millimetre. The same precision is highly applicable to bridge projects, says Mr Baltineshter.
SHS-Series SyncHoist: Enerpac's SHS SyncHoist system is a high precision hydraulic load hoisting and positioning system engineered to enhance crane performance and safety while reducing costs compared with conventional load positioning methods.
Available in system load capacities of 240, 320 and 440 tons, with system reach of 1500mm from each lifting point, SyncHoist offers very high accuracies (±1.0mm), less dependence on weather conditions and vastly improved operating speed and worker safety.
Enerpac high tonnage construction cylinders: including CLSG, CLS, CLL, and CLRG-series Cylinder lifting capacity ranges from 50 to 1,000 tons and supplies up to 10,000 psi. The high tonnage cylinder series features include an integral stop ring which provides piston blow out protection, safety lock nut for mechanical load holding and double acting for positive retraction.
Level Lift System: Enerpac's Level Lift System can control up to four lift points at once without complicated electronics or sensors at each lift point, making it easy to use and improving operator efficiency. It is designed for safe, fast, even and controlled lifting and lowering of uneven loads, typically up to 800 tonnes.
The Level Lift System is a fully configured and assembled system, which includes a ZE4 pump, hoses, gauges and cart. During operation, uneven loads are moved evenly as Enerpac's patented Level Lift valve sends a fixed volume of oil to each cylinder while lifting or lowering. Regardless of the distribution of weight in the application, or the resulting pressure at each lift point, the Level Lift System strokes each cylinder by the same amount. Each cylinder must have the same effective area.
Skidding Systems: Enerpac Skidding Systems are comprised of a series of skid shoes powered by hydraulic push-pull cylinders travelling over a pre-constructed track.
Enerpac skidding systems are usually custom-built to individual specifications but are also available in two standard versions:
Capacity per shoe
Stroke push/pull cylinders
600mm per stroke, 23.62in
600mm per stroke, 23.62in
Both standard skidding systems are available in two varieties, using either a skid shoe jack or a skid shoe beam. The skid shoe jack includes an integrated lifting cylinder. A skid shoe beam is designed for skidding purposes only.
Enerpac Caterroller Load Skates: Load skates are low profile load movers, designed to facilitate the moving and positioning of a wide range of loads such as heavy equipment, machinery and bridge structures.
Enerpac's heavy duty, rugged and sturdy load skates have low rolling resistance for easy transportation, low profile construction for increased stability and attachable load levelling plates and swivel turntables for turning corners.