PROJECT OVERVIEW

When the Northwest Rapid Transit (NRT) consortium– including MTR Corporation, John Holland, CPB Contractors, UGL Rail and Plenary Group – was awarded the operations, trains and systems contract for Stage 1 of the Sydney Metro Northwest line they contracted The Men From Marr’s to come up with a craneage solution that needed thinking outside the box, literally

Client NORTHWEST RAPID TRANSIT (NRT) CONSORTIUM
Project SYDNEY METRO (NORTHWEST) CASTLE HILL STATION
Location SYDNEY AUSTRALIA
Sector Major transport infrastructure
Date 2016-2018
Cranes
1 x M2480D 1 x M1680D
Engineers 2
Crane operators 6
Installation crew 6
Maintenance crew 2

THE CHALLENGE

Working alongside a 200m x 30m cut-and-cover station box in a congested site that was landlocked between two existing roads to lift loads weighing up to 60 tonnes.

MARR SYDNEY METRO NORTHWEST CASTLE HILL STATION

OUR SOLUTION

With a 330-tonne capacity M2480D and 200-tonne capacity M1680D installed along the station box, our solution provided lifting capacity across the entire site without the need for costly groundworks.

THE RESULT

Adopting our solution changed the way the entire project was constructed and has since become a new blueprint for other station builds on the Sydney Metro project.

The first crane is erected after working with NRT since initial discussions in April 2016 to develop the craneage methodology for the project. Our solution covered all aspects of the craneage requirements from design to installation, lifting and removal of the cranes on completion. Designed with efficiency in mind, the solution negated the need to move cranes around the job. This allowed the first crane (M2480D) to be installed, which was then used to install the second smaller crane (M1680D) and remove the cranes in the same fashion at the completion of the project. This meant we only had to take our large mobile crane onsite twice – for install and removal – helping to decongest the site and reduce costs to the client.

Castle hill1

A birds-eye view of the congested site showing the position of the M1680D (foreground) and M2480D (background) in relation to the station box. Designed to meet the geotechnical considerations of the site, the position of the crane foundations adjacent to the station box allowed the cranes to carry out lifts on both sides of the construction area.

Castle hill2

Using just two cranes in fixed locations, our methodology catered to the challenge of lifting elements weighing up to 60 tonnes, including some 50-tonne weights at the extreme ends and anywhere within and across the 200-metre station box.

MARR SYDNEY METRO NORTHWEST CASTLE HILL STATION 2

A critical consideration for the project was how to decongest the site. With cranes able to reach across the station box, we were able to facilitate a more efficient delivery unload and install process to lift pre-cast beams weighing up to 60 tonnes.

On completion we had successfully completed various lifts in addition to the heavy pre-cast beams, such as site machinery including mobile cranes, earth-moving equipment, concrete, reinforcing steel, and general construction materials required on a tunnel project of this magnitude.

Castle hill4

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We work with our clients to find a solution that works – no matter how big or complex the job is. And if the right crane doesn’t already exist, we’ll build one to suit the needs of your project.