CIVILS BROCHURE Together, we are Smarter, Safer, Stronger WORLDWIDE HEAVY TRANSPORTA 1 TION AND LIFTING

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

2 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 Risk Management in ALE through HSQE 10 Buildings 17 Bridges Installed with Barges 21 Bridge Jacking 24 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 3

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. 5

4 FRONT END ENGINEERING & DESIGN (FEED) 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

5 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, and 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. 9

6 BUILDINGS 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 in less than six hours. Once complete the three sections created an A-frame shaped building. 11

7 Buildings Lifting of a hangar roof, France Skidding of historic building, Mexico 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. 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. 13

8 Buildings Transportation of an Office Module, Heathrow Airport, UK Installation of the Arena Corinthians roof, Brazil 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. 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. 15

9 Buildings 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. 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 Installation of two 2,700t bridge arches Toruń, Poland OVERVIEW: ALE was contracted to complete the skidding, assembly and float installation of 2,700t arches over the 500m wide river Wisła, in Torun, 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. 17

10 Bridges Installed with Barges Load-out of bridge deck, The Netherlands Installation of Nacka Bridge, Sweden OVERVIEW: An iconic bridge designed by Santiago Calatrava has been successfully loaded-out by ALE in Krimpen aan den 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. 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. 19

11 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 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. 21

12 Bridge Jacking 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. 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. 23

13 BRIDGE LAUNCHING 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. 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. 25

14 Bridge Launching Launching of bridge Hennigsdorf, Germany Launching of the pavilion bridge Zaragoza, Spain 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. 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. 27

15 Bridge Launching Launching of the 700t Neditzer bridge, Germany Launching of parallel bridges, Canada 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. 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. 29

16 Bridge Launching 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 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. 31

17 LIFTING CENTRAL BRIDGE SPANS 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. 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 strand-lifting 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. 33

18 Lifting Central Bridge Spans 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 AK TILTING OF BRIDGE ARCHES 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. 35

19 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 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. 37

20 Transport of Bridge Sections with SPMT Transportation and installation of i54 bridge, UK Transportation and installation of rail 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. 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 off-line 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. 39

21 Tunnel Boring Machine TUNNEL BORING MACHINE 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. 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. 41

22 Bespoke Solutions BESPOKE SOLUTIONS 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. 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. 43

23 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 45

24 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 AUXILIARY, ANCILLARY & ACCESS EQUIPMENT HYDRO DECK MEGA JACK 800 SPMT SPT LIFTING SYSTEMS 47

25 WORLDWIDE HEAVY TRANSPORTATION AND LIFTING