Sarens was commissioned by our client to replace two overhead service crane beams installed in the 1940s. The biggest challenge was to work in a confined space with live equipment and limited information about the weight of the components to be removed.

Each step had to be meticulously calculated and precisely executed. Site inspections were conducted months in advance. The layout was arranged and planned to ensure no interference is caused during lifting, removal, and rotation of old beams and installing new beams. After careful analysis, the team deployed a hydraulic gantry system, hydraulic rotation unit, auxiliary pieces, and load cells. The equipment was mobilised from Sarens’ depot in USA in two transport loads and was assembled in two days addressing the limited space and ongoing operations at the generating station.

Two girders measuring 15.5m and having a maximum weight of 40T had to be removed. These girders were installed in the 1940s and had auxiliary equipment attached. Hence, there was limited information available about the exact Centre of Gravity (COG) values of the load – leading to a lifting challenge.

Sarens’ engineering team was present onsite during the removal stage to closely monitor the weight of the girders and adjust the lifting plan in real-time. The equipment picked up the girders at a height of 10m, freeing it from the rails. They were then rotated 90 degrees for clearance using a hydraulic turntable. Once lowered, the girders were removed with the help of an assisting crane. The same operation was repeated in reverse order during the installation.

Benjamin Pavich, representative from the client reacted, “Flawless and safe operation - we removed and installed the overhead crane beams in record time”. Carter El-Fityani, Sarens Project Manager added, “This was indeed a great project where we delivered remarkable service adjusted to the safety, schedule, and cost requirements of the client.”