CIVILS BROCHURE

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CIVILS BROCHURE

Together, WORLDWIDE we are Smarter, HEAVY Safer, TRANSPORTATION Stronger AND LIFTING 1


Together, we are...

CONTENTS

Smarter

Safer

Stronger

At the heart of ALE’s business are our people: dedicated professionals who work

with our clients to achieve the very best results. We employ imaginative people at

all levels within the company, who focus on developing innovative solutions for the

most complex projects. We challenge conventional thinking, aspire beyond accepted

limitations, and don’t stop until we have the smartest, most effective solution to each

and every challenge. Our Innovation Series is just one example of our insistence on

pushing the boundaries to create solutions that work best for our clients.

ALE is a responsible business with a strong moral core, so the safety and well-being of

the individuals we work with and the clients we work for is our single most important

consideration. Minimising risk to our staff, our clients and members of the local

community is a priority at the highest level of the company, and an ethos that

permeates every aspect of our business.

We haven’t become one of the world’s foremost experts in heavy transportation and

lifting by thinking small. By investing in the latest technologies and employing the

best people in the business, we’ve grown over more than 30 years into a global leader

with a presence across a breadth of sectors and markets. Our flexible approach suits

any project, whatever its size or scale, and our clients know they can rely on us for

commitment, innovation, delivery, service and an agile, proactive approach that

gets results.

04 Introduction

06 Front End Engineering & Design (FEED)

08 Health, Safety, Quality

& Environment (HSQE)

10 Buildings

17 Bridges Installed with Barges

20 Bridge Jacking

23 Bridge Launching

31 Bridge Skidding

32 Lifting Central Bridge Spans

35 Tilting of Bridge Arches

37 Transport of Bridge Sections

with SPMT

40 Tunnel Boring Machine

42 Bespoke Solutions

44 Sectors

45 Services

46 Equipment

47 Innovation Series

Together, we are Smarter, Safer, Stronger

3


INTRODUCTION

Civil activity represents a key segment of ALE´s portfolio.

With vast experience in projects such as the removal and installation

of innovative road, rail, river and canal bridges, lock gates, stadium

roofs and airport architecture, ALE has an in-depth understanding of

the highly specialised engineering involved in the safe and accurate

execution of civil projects.

An appreciation of the control of loads and their distribution, a fleet of Self-Propelled

Modular Transporters (SPMTs), proven expertise in lifting, skidding and jacking

techniques and meticulous project management means ALE is well equipped to move

enormous structures with minute precision.

ALE is always looking at innovative solutions and designing bespoke equipment to

ensure that the best result for the client is found, this innovative thinking and close

working with the client can often change the project to save on time and costs.

ALE is actively participating in most of the biggest civil investments all over the

world; through innovation and first class engineering we enable clients to push the

boundaries of construction methods.

Together, we are Smarter, Safer, Stronger

5


FRONT END ENGINEERING & DESIGN (FEED)

1. 2.

With a pedigree in innovative engineering and an active R&D facility, ALE

has always been known for developing new solutions to meet future needs.

In other market sectors ALE is actively involved in the FEED process. Over the years we’ve added to

our world-class engineering skills-base through the acquisition of several successful specialist

companies, and now we have more than 200 highly qualified engineers working at locations across the

globe. This experience means we’re well equipped to support the full FEED process, working through

complex technical and logistical issues at an early stage to eliminate expensive changes later on.

Our FEED capabilities form a crucial part of the service we offer. ALE has contributed to many high

profile projects that have been right at the forefront of global trends in their sector. We are able to

adapt to ever-changing industry requirements, evolving safety standards and scope changes as the

project gathers definition during the design process, while at the same time providing solutions which

are as cost-effective and safe as possible. As a result, we’re able to work closely with our clients from

an early stage to establish what’s required and provide practical engineering advice. This advice can

lead to savings later, either in time or cost, as the changes are included in the design phase, instead of

modifications later.

Some of our FEED services typically include, but are not limited to, the items below:

• Physical route surveys to determine maximum practical equipment

weight and dimension information

• Investigation of environmental conditions affecting the heavy lifting

and transport discipline

• Road layout and route improvement studies

• Advice on local regulatory issues relating to the movement of large

and indivisible loads to the job site

• Equipment lifting and installation studies to determine the most cost

and schedule effective methods of sizing and placing equipment

• Design of rigging and lifting equipment

• Outline design of new build site construction jetties

• Selection of optimum shipping methods and identification of

suitable vessels or barges

• Logistical studies to ensure that transportation and installation

scope support the project schedule

• Design and input to design of transportation support steel and

lifting and lashing/securing points

• Assistance in modularisation studies to determine the maximum

practical extent that man hours can be removed from the job site

• Assistance in modularisation studies to determine the maximum

practical extent man hours can be removed from the job site

3. 4.

Together, we are Smarter, Safer, Stronger

7


RISK MANAGEMENT IN ALE THROUGH HSQE

We recognise that the industries and sectors that we operate in present challenges in terms of

managing risk. Our passion is fuelled by our history and foundation in protecting our people,

environments and assets all over the globe.

ALE is cemented in a context of over 30 years of evolving Risk Management though maturing

legislation, international standards and client requirements. We as ALE see the value in a safer

working environment for all and we want to capitalise on our history and better mitigate industry risks.

By investing in our constantly evolving internal infrastructure, we are able to maintain our competitive

advantage with industry leading initiatives that allow us to implement and use breakthrough tools to

identify, assess and act upon all levels of risk to our people, environments and assets. This has given

us the ability to identify areas that require attention as well as nominate single areas of concern to

target resources.

ALE are committed to lead the industry and influence all of our clients and subcontractors in a united

approach to achieving an incident and injury-free mindset. In order to achieve this, we have developed

and adopted many of the leading systems and processes that are seen as industry best practice and

available techniques.

We have ensured that our core systems which shape the way we operate are certified and proven

to comply with ISO 9001, 18001 and 14001. ALE know that it is imperative to not only attain the

certification but to also have a robust assurance process in place to ensure that the standards are met

and maintained.

At ALE, we realise that this journey is not to be taken in isolation, therefore we stand by the fact that

together we are safer.

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Together, we are Smarter, Safer, Stronger

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BUILDINGS

CASE STUDY

Jack-up of roof section in Pascua-Lama,

Chile and Argentina border

OVERVIEW: ALE has completed the jacking of roof sections for the stockpile building

in the Pascua-Lama mine at the Chilean Argentina border. This was the first time

ALE’s Mega Jack was used.

SERVICES REQUIRED: The stockpile roof was located at 4,200m altitude and within

an earthquake area, making the environmental conditions extremely harsh and

challenging, including high wind speeds, temperatures ranging from -30 to +20 and

air pressure as little as 0.6 bar. As a result, all of the girders were pre-assembled into

40t heavy truss sections near San Juan at normal altitude and transported to the

installation site. The method used to construct the roof of the building was also a first.

ALE then used the Mega Jack System to raise the roof in three sections weighing

1,500t each. Due to the unique way in which the roof was to be installed, ALE utilised

four towers of the Mega Jack System – with a total capacity of 20,000t and ten 90t

capacity hydraulic skid shoes. With possible wind speeds of up to 150km/hr ALE took

additional precautions by installing a guy wire system consisting of four 200t strand

jacks at each end of the building to withstand high winds.

The roof of the building was positioned in three sections above the ground on

temporary stands. A hydraulic skidding system was used to support and move the

side girders inwards. ALE positioned the skid systems at each end of the building

while the main inner section of the building was lifted 18m to the final position by

the Mega Jack. As an extra precaution against the extremely strong wind, eight 200t

strand jacks were installed cross wise at each side of the stockpile building.

The jack-up operation, which consisted of 22 layers of beams, was completed inless

than six hours. Once complete the three sections created an A-frame shaped building.

Together, we are Smarter, Safer, Stronger

11


Buildings

CASE STUDY

Lifting of a hangar

roof, France

OVERVIEW: ALE was commissioned by

a leading aircraft manufacturer to lift

their S34 hangar roof in Toulouse, France.

SERVICES REQUIRED: ALE performed

the lifting of the hangar roof, with

an estimated weight of 2.5t and vast

dimensions measuring 110x105m

from above.

The lifting execution, reaching 28m,

utilised sixteen 200t capacity lifting

units within a six-hour time frame.

CASE STUDY

Skidding of historic

building, Mexico

OVERVIEW: ALE was responsible for skidding

a historic building, protected by the Fine Arts

of Mexico, in order to free space to build a

car park. Once the car park was completed,

the 2,500t house was then skidded back to its

original position.

SERVICES REQUIRED: We used the SKS1000

skidding system, composed of modular skid

tracks and 6 skidshoes with a total length of

46m per line. Each skidshoe incorporated

two 500t capacity vertical hydraulic cylinders

with a stroke of 300mm.

The house was jacked up 50mm in order

to remove the temporary supports, skidded

17m and placed back on temporary supports

whilst the car park was built. During this

time, the total weight of the house was

supported by the skidding equipment.

The temporary supports were then

removed and the house skidded 17m back

to its starting point. The final process was

for ALE to complete the jacking down to

ground level.

Together, we are Smarter, Safer, Stronger

13


Buildings

CASE STUDY

Transportation of an Office

Module, Heathrow Airport, UK

OVERVIEW: ALE completed the move of an office

module at Terminal 2, Heathrow Airport.

The scope of work was to transport the module

weighing 1,100te over 2km across the airport firstly

to a temporary storage location before finally

moving to its new permanent position.

SERVICES REQUIRED: The dimensions of the

accommodation module were 54m x 24m x 11m. To

manoeuvre a piece of this size, ALE used 108 axle

lines of SPMT to navigate the route.

Due to the construction of the building ALE had

to ensure that the deflection of the module base

was within + or – 50mm over the 54m length of

the structure. This was completed through close

monitoring during the move.

Phase one involved self-loading 108 axle lines

of SPMT by driving underneath the module and

transporting it from its location to a temporary

storage location 500m away. The move took place

from 10pm, after the last plane had taken off from

Terminal 2.

Phase two began when the foundations had been

transported to the permanent location, the two

gates were reopened and the following two gates

had been closed. The move involved transporting

the module from the temporary storage area to

its permanent location 1.5 km away; this involved

transporting the piece across the runway.

CASE STUDY

Installation of the Arena

Corinthians roof, Brazil

OVERVIEW: ALE completed the lowering

of the roof structure at the Arena

Corinthians, Brazil.

SERVICES REQUIRED: The first stage of

the project saw ALE install and utilise two

strand jacks, of 70t capacity, side by side

to create a tensioning system.

This system allowed the cable section

to be manufactured and installed. ALE

were then required to use ten jacks,

ranging from 300t – 500t capacity, to

lower the north and south sides of the

stadium to complete the installation.

The interim towers were then able to

be removed.

Together, we are Smarter, Safer, Stronger

15


CASE STUDY

Elevation of Els

Encants roof, Spain

OVERVIEW: ALE has successfully lifted

the first section of roof for the new

market ‘Els Encants’ to its final elevation

in Barcelona, Spain.

SERVICES REQUIRED: The total weight

of the completed roof was 1,226t, which

posed a challenge for elevation.

Due to assembly issues, the lifting of the roof

was divided into eight sections with six of

the eight involving gradual lifting in stages

using hydraulic lifting units installed over each

supporting pillar.

The final two sections were lifted into place

using mobile cranes. By elevating this way, the

roof can be completed on the ground.

Once each section was lifted and installed, the

system was removed and reinstalled over the

next set of supporting pillars, enabling each

section to be lifted individually.

The first section lifted was 115m long, lifted

10.8m high and required fourteen lifting units

for elevation. Thirteen strand jack-lifting units

(HLS700) and one HLS2000 unit were

also utilised.

Buildings

The operation was completed in less than three

hours and the remaining roof sections will be

lifted when they have been built.

BRIDGES INSTALLED

WITH BARGES

CASE STUDY

Installation of two

2,700t bridge arches

Torun, Poland

OVERVIEW: ALE was contracted to complete the

skidding, assembly and float installation of 2,700t

arches over the 500m wide river Wisła, in Toruń,

which will become a traffic bridge and is a major

investment in the region.

SERVICES REQUIRED: ALE began by jacking up the

two sections of the first arch from the fabrication

supports using eight 500t capacity climbing jacks

which were placed on skid beams; the sections

were then skidded towards each other and

connected with two centre hinges. A 55m high

ALE gantry system was built up over the arch

sections. The 1,350t capacity gantry utilised four

500t strand jacks connected with the anchor heads

to the hinge point of the bridge. Four barges were

used for supporting the bridge in sets of two; each

contained a support structure of approximately

12m in height. On top of this support structure the

ALE jacking towers were installed, with a capacity

of 1,600t per barge set.

Throughout the operation careful monitoring

was carried out as the river is well known for

unpredictable water height and high water speed.

Multiple hydraulic winches were used to rotate the

bridge, and float it to its jacking position. On the

second day ALE jacked-up the arch 14m to its final

installation height on the abutments. The jacking

operation was executed simultaneously with the

jacking towers and all bracing strand jacks. From

here ALE followed an identical process to install

the second bridge arch.

Together, we are Smarter, Safer, Stronger

17


Bridges Installed with Barges

CASE STUDY

Load-out of bridge deck,

The Netherlands

OVERVIEW: An iconic bridge designed by

Santiago Calatrava has been successfully

loaded-out by ALE in Krimpen ad IJssel, Holland.

SERVICES REQUIRED: The bridge deck, which

weighed 2,490t, was loaded-out using 125 lines

of SPMT and roro ramps. The trailers hydraulic

system raised the bridge from its supports to

begin the load-out. During operations, ALE

supplied a deck-ballasting system at a capacity

of 1,200t per hour.

Once the load-out was complete, the bridge

was lowered back down gradually onto the sea

fastenings. This was done precisely to ensure

stability and cargo security. The support of four

climbing jacks was used alongside a skidding

system within the sea fastening.

The bridge deck was then transported to Dublin

on a barge. Once it arrived and had been

ballasted, it was skidded backwards to create

an opening for its pivot.

Wires were then connected to manoeuvre it

alongside the pivot. It was then rotated over

the pivot and lowered onto the support and

tidal curve.

CASE STUDY

Installation of Nacka

Bridge, Sweden

OVERVIEW: ALE has successfully installed

Nacka Bridge, weighing 1,650t, in Sweden.

SERVICES REQUIRED: Nacka Bridge, a curved

arch bridge measuring 140m long and 25m

high, was installed in several phases:

PHASE ONE: The bridge was transported 100m

through the narrow construction site using

turntables on top of 32 axle lines of SPMT

positioned at the back of the bridge and 48

axle lines of SPMT positioned in the centre.

PHASE TWO: The first barge was positioned

underneath the bridge arch, where it

supported 960t of bridge weight using

winches connected to anchor points at sides

of the riverbank. By ballasting and extending

the jacks on top of the barge, the weight of the

bridge was transferred from the front SPMTs

to the barge. On the barge, two jacks were

used to support the load and stabilise the

barge in the transversal direction.

The SPMTs were then removed from

underneath the bridge and the winches kept

the barge sideways. As the barge moved to

the other side of the river, the second barge

was positioned under the bridge.

PHASE THREE: ALE ballasted the barge until the

1,300t bridge weight was transferred onto the

barge. Strands were installed from the bridge to

strand jacks connected to the barge to stabilise

the barge in a transversal barge direction.

ALE removed the first barge using the winches

and a tugboat as the bridge continued to move

to its final position using the driving capacity of

the SPMTs at the rear of the bridge.

PHASE FOUR: The bridge was be jacked down

3.5m to its final elevation.

Together, we are Smarter, Safer, Stronger

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CASE STUDY

Installation of the Carl-Urich

Bridge, Germany

Bridge Launching

OVERVIEW: The installation of the Carl-Ulrich

Bridge in Offenbach am Main, Germany, has

been successfully completed by ALE.

SERVICES REQUIRED: Jacking up the bridge

and preparing the transportation

Weighing 1,100t and measuring 150m long,

the new bridge was built on the quayside.

The bridge was jacked up 1.6m using four

500t capacity climbing jacks. 48 axle lines

of SPMT were prepared with supporting

construction and positioning underneath the

bridge. Hydraulic jacks were placed on top of

the frame to be able to compensate for the

deformation of the bridge.

BRIDGE LOAD-OUT: The bridge was loaded

out onto the SPMTs and driven onto two, 66m

x 11.5m barges. Each barge was fitted with a

bespoke combination of four winches and four

fairleads to guide the winch wires, along with

a hydraulic powerpack and generator to power

the winches.

BRIDGE INSTALLATION: The bridge was

transported from the quayside to its final

location across the river Main by rotating

the bridge 90 degrees and connecting each

barge to the river bank with four winches,

which were then used to guide the bridge,

SPMT and barges to the installation position

of the bridge. During this process, the anchor

points of some winches were changed in

between phases. When the final position was

reached, the bridge was then lowered into its

foundations by ballasting the barges.

BRIDGE JACKING

CASE STUDY

Rail bridge

replacement, UK

OVERVIEW: ALE replaced a 500t railway bridge

in Liverpool as part of a track upgrade.

SERVICES REQUIRED: The bridge decks which

were adjoined to Liverpool Sandhills station

were removed using twenty eight axles of

SPMT. ALE integrated sixteen 100t capacity

climbing jacks into the transport arrangement,

to ensure height requirements over the

abutment wall.

To complete the project the old and

replacement bridge decks were required to

be manoeuvred around the station platform

and beneath a temporary walkway bridge.

ALE used various configurations of SPMT to

achieve the limited space manoeuvres, ALE

also had to ensure that no loading was applied

to the large section of pavement that needed to

be crossed, this was achieved by transporting

them across bridging mats. The decks were

then offloaded to high level trestles where they

would then be jacked down for demolition.

The 270t replacement bridge decks which were

previously jacked up to installation height in

preparation were removed from the trestles

using sixteen axles of SPMT complete with

high level trailer steelwork.

Together, we are Smarter, Safer, Stronger

21


Bridge Jacking

CASE STUDY

Dual bridge jacking on

the A31 highway, Spain

OVERVIEW: ALE has successfully

performed the jacking of two 1,000t bridges

on the A31 highway in Albacete, Spain.

SERVICES REQUIRED: The bridges,

each weighing 1,000t, are statically

indeterminate meaning the jacking

supports had to be installed at each pillar

side by means of high capacity structures

that enabled the reduction of rigging time.

ALE elevated the bridges to a height of

550mm from 16 points and used 12,300mm

stroke jacks and two climbing jacks

installed at the different abutments. An

electronic stroke control system controlled

the overall operation.

CASE STUDY

Exchange of the Loenerslootse

Bridge over the Amsterdam-Rijn

Canal, The Netherlands

OVERVIEW: ALE has completed the load-out,

transportation and installation of the new 1,570t

Loenersloote Bridge and the removal of the

1,630t old bridge over the Amsterdam-Rijn canal.

SERVICES REQUIRED: The Loenersloote Bridge

exchange was undertaken in several phases:

PHASE ONE: The 1,050t, 124m long arch bridge

was loaded-out onto a 66m x 19m barge, using

forty-four axle lines of SPMT.

PHASE TWO: Two cranes installed the two

20m approach spans which extended the bridge

to a length of 144.6m and increased its weight

to 1,250t.

PHASE THREE: The arch of the bridge was

removed. The bridge deck was transported 120km

to Nigtevecht on three connected barges and an

inland vessel was used to transport the arch.

PHASE FOUR: The bridge arch was assembled

at Nigtevecht using two cranes to lift the arch

off the vessel. This vessel was then removed

and the bridge deck was positioned underneath

the arch. The Mega Jack 800 jacked-up the new

bridge to 9m from the barge deck.

PHASE FIVE: The old bridge approach span was

removed using a gantry system over the rail track

and was transported using 20 axle lines of SPMT.

PHASE SIX: There were 2 x 4 hour periods when

the canal was closed for inland navigation for

the old bridge to be removed and new one

installed. The new 330t bridge approach span

was transported using 20 axle lines of SPMT.

The old bridge was jacked down to demolition

height using the Mega Jack 800. The operation

took just 7.55 hours.

Together, we are Smarter, Safer, Stronger

23


BRIDGE LAUNCHING

CASE STUDY

Bridge launch over the

Nalon River, Spain

OVERVIEW: ALE successfully completed

the launch of a bridge over the Nalon

River, Soto del Barco, Spain. The viaduct

itself was a total length of 1,010m and

weighed 5,500t.

SERVICES REQUIRED: To complete

the project ALE used skidding systems,

strand jack units, telescopic hydraulic

jacks and a mast system.

CASE STUDY

Launching of ‘Los

Carneros’ viaduct, Spain

OVERVIEW: ALE has completed the

launching of the ‘Los Carneros’ viaduct

over the Guadiana River in Spain. The

bridge weighed a total of 3,500t and

consists of five spans.

SERVICES REQUIRED: The Bridge was

launched in phases from the abutments

and over the river. ALE utilised 90m of

skidding equipment, hydraulic skidding

supports, hydraulic pulling units, towers

and jacking system. The bridge reached

across a length of 561m and each phase

was completed within four days.

Together, we are Smarter, Safer, Stronger

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Bridge Launching

CASE STUDY

Launching of bridge

Hennigsdorf, Germany

OVERVIEW: ALE launched a 1,100t railway

bridge over the Oder Havel Canal in

Hennigsdorf, Germany in a complex

installation that included a combination

of land, rail and water transport.

SERVICES REQUIRED: In the first phase of

the transport, the 101m bridge structure

was lifted 10m using four gantries, each

with a 500t stand jack. The bridge was

then skidded transversely 24m over

railroads tracks. In order to support the

skid ways, ALE installed bridging beams,

supported by jacks, to compensate for the

expected settlement in the foundations.

Once the bridge was centred on the rail

tracks, it was jacked down 1.5m onto the

32 rail bogies. The bridge then needed to

be transported the 500m to the quayside

by rail.

CASE STUDY

Launching of the pavillion

bridge Zaragoza, Spain

OVERVIEW: ALE were contracted to launch

a bridge in the city of Zaragoza to enable

visitors access from the city to the

exhibition facility.

SERVICES REQUIRED: The total weight of the

bridge was 2,400t and was created with an

asymmetrical design meaning that the bridge

itself was able to bend in various directions,

this was a variant taken into account when

the engineering solution was designed

by ALE.

ALE utilised skidding systems, jacking and

pulling mast systems to execute the launch

and pull of the bridge across the river.

Together, we are Smarter, Safer, Stronger

27


Bridge Launching

CASE STUDY

Launching of the 700t

Neditzer bridge, Germany

OVERVIEW: ALE won the contract to

install a 700t bridge over a river in

Potsdam, Germany.

SERVICES REQUIRED: ALE used SPMTs

climbing jacks, skidding plates, strand

jacks and a 400t crane to complete

the project.

Firstly ALE positioned two stationary

skidding plates under the front of the 85m

bridge onto ALE jacking towers whilst

SPMTs were installed at the rear of the

bridge. Strand jacks were then utilised at

the end of the bridge to launch the load

39m across the river. A 400t crane was

then used to take the weight of the bridge

and manoeuvre to its final position where

climbing jacks took over to ensure the

piece was jacked down to the foundations.

CASE STUDY

Launching of parallel

bridges, Canada

OVERVIEW: ALE has successfully launched two

parallel bridges spanning the 1,500m width of

the Beauharnais canal, Canada. The steel bridges

weighing 7,100t were each launched into place

using ALE’s skid system to become part of the

new highway 30 in Quebec, Canada.

SERVICES REQUIRED: The bridges were skidded

out using 300t jacks; the skid system was the most

suitable for this project because of the effectiveness

and accuracy when moving such big pieces.

ALE also installed a recovery deflection system

consisting of a mast linked by steel wires to the

structure using two 850t capacity strands jacks.

Each bridge had an auxiliary launching nose of 20m

in order to minimise the cantilever and provide a

stable operation. Each bridge was launched across

the 19 bridge piles which were mostly 82m apart

with the exception of the commercial crossing

section of the canal which was 160m between

piles, in addition to this the incline from one side

to the other was up to 3% which needed to be

taken into account. The equipment used for the

project included strand jacks ranging from 70t –

850t capacity, 35m high mast, 640m hydraulic skid

system, and hydraulic sliding supports.

Together, we are Smarter, Safer, Stronger

29


Bridge Launching

CASE STUDY

Launching of an 860t HST

bridge over the suburban

train network at Atocha

station, Spain

OVERVIEW: ALE successfully completed

the launching of a bridge for the high

speed train access over the suburban train

network and Comercio St at the Atocha

station (the largest HST train, subway and

suburban train network in Spain).

SERVICES REQUIRED: The launching of the

bridge was performed with four SKS300

skid shoes with a capacity of 300t each;

push pull units, six stationary sliding

systems, four 30t supports to be used for

deflection recovery, and 140t jacks with a

stroke of 250mm.

BRIDGE SKIDDING

CASE STUDY

Transversal skidding of

a railway bridge in

Vitoria, Spain

OVERVIEW: ALE was contracted to install

a 3,500t replacement rail bridge in Spain.

SERVICES REQUIRED: The new bridge was

built in order to minimise the interruption of

the rail line from Madrid-Paris. The new bridge

had a span of 100m and weighed 3,500t and

was composed of concrete and

a steel arch.

The complete installation including the

ballasted tracks and the electrical installation

was completed by ALE engineers. The closure

of the railway started at 4am after passing the

night train Madrid-Paris. The original bridge

was disassembled by crane and the new one

was skidded up to its final position, being

ready and operating at 6pm on the same day.

Together, we are Smarter, Safer, Stronger

31


LIFTING CENTRAL

BRIDGE SPANS

CASE STUDY

Floatation, navigation

and installation of bridge

sections, Spain

Bridge Skidding

OVERVIEW: ALE performed the installation

of two 60m long bridge sections each

weighing 210t over the Pisuerga River

in Valladolid, Spain. The bridge adds

pedestrian and bike paths to each direction

of traffic.

SERVICES REQUIRED: ALE used a CC2800

crane with 280t of counter load to lift

the bridge sections and place them on

a flotation platform. The bridge sections

were then navigated below the bridge

abutments, and the final lift was completed

using HLS700 strandlift units located on the

bridge abutments. The two sections were

lifted separately over two consecutive days.

CASE STUDY

Vicaria bridge lifting,

Spain

OVERVIEW: The 500t Vicaria Bridge in

Albacete, Spain was lifted by ALE over

the course of one day.

SERVICES REQUIRED: Using an auxiliary

steel structure and four HLS200 strandlifting

units each with a capacity to lift

200t, ALE successfully lifted the Vicaria

bridge in Albacete, Spain.

The bridge was elevated to a height

of 40m.

Together, we are Smarter, Safer, Stronger

33


Lifting Central Bridge Spans

CASE STUDY

Olympic Park Transformation

Project, UK

OVERVIEW: As part of the Olympic Park

transformation, ALE completed the first bridge and

portal removal for this project.

SERVICES REQUIRED: The Gottwald AK912-1 fitted

with a 77m Maxi Boom and 400t Maxi Lift Ballast

removed the T12 bridge, which was the main link

between the Stratford coach park and drop off

point into the Olympic Park.

The bridge and portals were removed on three

consecutive days. ALE engineered a solution to

allow the portals, which were erected in three

sections, to be removed as one piece using the

AK912-1.

TILTING OF

BRIDGE ARCHES

CASE STUDY

Tilting of arches for

the viaduct over the

Tera River, Spain.

OVERVIEW: ALE has completed the

tilting of two steel semi-arches, P2 and

P3, for the viaduct over the Tera River

in Zamora, Spain.

SERVICES REQUIRED: P2, which formed

part of the bridge’s central deck section,

weighed 303t and measured 84m in

length. P3 weighed 272t and measured

81m in length. In order to perform the

tilting, two hydraulic units of 500t each

were used per semi-arch, along with

a pair of auxiliary telescopic jacks to

start the operation and to break the

initial arches’ balance.

Four double effect jacks, of 300t

and 150mm stroke, were installed at

each swivel base of the two semi-arches.

This was carried out to set the

longitudinal movements of the arches in

order to carry out the final adjustment.

Together, we are Smarter, Safer, Stronger

35


CASE STUDY

Alcántara Dam, Spain

Tilting of Bridge Arches

OVERVIEW: ALE was appointed to assist

with the construction of a viaduct on

La Plata highway over the Tajo River.

SERVICES REQUIRED: The viaduct consists

of two main sections with a total length

of nearly 400m, which are supported on

concrete pillars rising from the banks of the

river and from steel arches in the centre.

ALE’s responsibilities included pushing

the bridge sections into place, skidding the

steel arches over the bridge and lowering

them into position, tilting and closing the

semi arches, skidding the semi-decks from

both abutments and replacing.

TRANSPORT OF

BRIDGE SECTIONS

WITH SPMT

CASE STUDY

Arch installation of

Rego de Lamas

Viaduct, Spain

OVERVIEW: ALE has completed the arch

installation of the Rego de Lamas Viaduct

in Orense, Spain.

SERVICES REQUIRED: ALE were

commissioned to perform the installation

of the arch section of the Rego de Lamas

Viaduct in Orense, Spain. The arch

section measured 80m and weighed

approximately 1,100t.

ALE built the section on a platform over

the right bank of the AP-53 highway, which

runs towards Orense and created a slope

similar to the AP-53 highway.

For the project, ALE utilised SPMT trailers

and a supporting steel structure to

stabilise the bridge section. The load was

then lifted and unloaded over the supports

before being transported to the assembly

area.

Trailers and 300t climbing jacks were

used for the lowering until the structure

was finally jacked down and repositioned.

The project was a huge success with

the crossing manoeuvre only taking two

hours to complete.

Together, we are Smarter, Safer, Stronger

37


Transport of Bridge Sections with SPMT

CASE STUDY

Transportation and

installation of i54

bridge, UK

OVERVIEW: ALE completed the transportation,

and installation of an integral piece of

infrastructure for the i54 project in

South Staffordshire.

The i54 project has had considerable

investments by three local councils which will

see the 226 acre site become a major business

park creating hundreds of jobs in the area. We

were contracted to transport and install a 45m

long bridge which replaced a previous bridge

in Middle Lane and will allow access to what

will be a new motor engine plant and water

treatment works. The bridge will also serve as a

public footpath and bridleway across the M54

near Wolverhampton.

SERVICES REQUIRED: The bridge was

installed in a night move with a partial road

closure between junctions 2 and 3 of the M54.

Twenty four axles of SPMTs were utilised to

transport the bridge a quarter of a mile from its

fabrication position within the I54 compound to

its final installation point over the M54.

CASE STUDY

Transportation and

installation of rail

bridge, UK

OVERVIEW: ALE moved a railway bridge into

place to make way for the new Selly Oak

New Road to pass underneath and relieve

the chronic congestion faced by commuters

on the A38.

SERVICES REQUIRED: The new 70m three

span railway bridge was constructed offline

on a temporary 10m high embankment

before being transported into position using

ALE’s SPMTs.

The new structure carries the Birmingham

to Gloucester rail line across a 15m deep

cutting, which will contain the new road.

Weighing in at 3,945t, the move and

installation of the concrete deck is believed

to be one of the heaviest bridge moves using

SPMTs in the UK.

Together, we are Smarter, Safer, Stronger

39


Tunnel Boring Machine

TUNNEL BORING

MACHINE

CASE STUDY

Installation of a TBM,

Madrid

OVERVIEW: ALE successfully oversaw

a project that tilted a bearing house of

a tunnel-boring machine weighing 700t

in Madrid.

SERVICES REQUIRED: Utilising a steel

structure and a skidding system of 150t

capacity plus two 500t lifting units for

the lifting operation and four 70t lifting

units for tilting. The project ran smoothly

and to plan.

CASE STUDY

Installation of a TBM,

Las Vegas

OVERVIEW: ALE performed the installation of

a TBM in Las Vegas. The operation involved

several manoeuvres to consecutively introduce

each section into the cavern prior to assembly.

SERVICES REQUIRED: The project was carried

out in phases, firstly the frontal shield was

skidded 15m by means of skidding gantry to

reach the hatch. The shield was then lowered

200m into the hatch, the lowering was

monitored by cameras and water levels to

ensure the piece would not be damaged.

The next section to be lowered was the bore

head weighing 115t; this was skidded to the

hatch and tilted before being lowered the 200m

inside. Once inside the frontal shield and bore

head sections were placed into the assembly

position. The pieces where then skidded

toward each other using a skidding system

and the hydraulic lifting units of the gantry

simultaneously. Following intermediate

sections were lowered into the cavern.

The 70t rear shield was tilted into the hatch

using a skidding gantry and auxiliary crane;

it was lowered down inside the cavern and

aligned for welding. The sections were then

assembled and using longitudinal skidding, the

complete 950t TMB was maundered 20m using

eight skid shoes.

Together, we are Smarter, Safer, Stronger

41


Bespoke Solutions

BESPOKE SOLUTIONS

CASE STUDY

Pillar-box unloading, UK

OVERVIEW: ALE unloaded two pillar-boxes

weighing over 450t each which belong to

the main piles of the new Forth Replacement

Crossing in Scotland.

SERVICES REQUIRED: Before work began,

a test was conducted on the loading of the

mast. It was carried out with a 5% overload

and 36m radius.

ALE utilised a lifting system connected to

the main mast with a capacity to lift 560t at

a radius of 36m. The mast was supported at a

distance of 64m to the rear by two HLS5000

units, which allowed for lifting or lowering.

The retaining units and the main boom were

placed onto resistant bulkheads on the barge.

Over the bulkheads, a structure was installed

to spread the load along the barge’s reinforced

bulkheads.

To lift and lower each piece, two HLS5000

units were installed at the top end of the mast.

A modular adjustable lifting beam with a

capacity to lift 250t was also installed.

ALE then assembled the mast on the barge in

a horizontal position over temporary supports.

An auxiliary crane was used to perform the

vaulting of the main mast.

CASE STUDY

Bridge uprighting over

the Cuarto River,

Argentina

OVERVIEW: Two steel towers that make

up the new 190t bridge over the Cuarto

River in Argentina have been successfully

uprighted by ALE.

SERVICES REQUIRED: The operations

began with ALE utilising a swivelled gantry,

which incorporated an axis of rotation at

the base to enable simultaneous rotation

as the tower was lifted.

In addition to this, five lifting units were

required for the elevation of the tower and

a final 70t unit was used for retaining as

the centre of gravity passed over the axis

of rotation.

Together, we are Smarter, Safer, Stronger

43


SECTORS

SERVICES

CIVIL

MINERALS & METALS

NUCLEAR

BALLASTING

CRANE LIFTING

ENGINEERING

JACKING

OFFSHORE

OIL, GAS & PETROCHEMICAL

PORTS

LIFTING SYSTEMS LOAD-IN & LOAD-OUT LOGISTICS

MARINE ENGINEERING

POWER GENERATION

RENEWABLES

SHIPYARDS OFFSHORE INSTALLATION

SKIDDING TRANSPORTATION TURNKEY OPERATIONS

WEIGHING

Together, we are Smarter, Safer, Stronger

45


EQUIPMENT

INNOVATION SERIES

CRANES

SKID SYSTEMS

WEIGHING SYSTEMS

SPECIALIST

CRAWLER

MOBILE

TRANSPORTATION

BALLAST SYSTEMS

JACKING SYSTEMS

MEGA JACK

AL.SK CRANES

ALL TERRAIN TRANSPORTERS

GIRDER FRAME

MODULAR TRAILERS

BARGES

AUXILLARY, ANCILLARY &

ACCESS EQUIPMENT

HYDRO DECK MEGA JACK 800

SPMT

SPT

LIFTING SYSTEMS

Together, we are Smarter, Safer, Stronger

47


INFO@ALE-HEAVYLIFT.COM

WWW.ALE-HEAVYLIFT.COM

WORLDWIDE HEAVY TRANSPORTATION AND LIFTING

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