An interesting example of Australian ingenuity and getting things done
on time, recently emerged at the Hay Point Coal Terminal, 30km south
of MacKay on the Central Queensland coast.

The engineers a ThyssenKrupp, the company selected to design and build the new reclaimer at the Hay Point Coal Terminal, believed a better and faster way could be found to build the main boom, finish it by adding all components and then, in its completed state, attaching it to the Stacker / Reclaimer.

Having developed a revised way of assembling their new machine, ThyssenKrupp engineers then called in BOOM Logistics Heavy Haulage Division, to see if their idea could be made to work ... and if BOOM had the unique equipment required for this procedure.

"Previously, with this sort of project, the building process would involve the 60m long boom being progressively assembled after attaching the base unit of the boom to the machine," explained Mr Peter Chapman of ThyssenKrupp.

The alternative process that the ThyssenKrupp engineers visualised was one of building the boom of the reclaimer at ground level and, when more-or-less completed, moving it close to the machine and then lifting it up and into position for attaching to the slewing deck of the reclaimer.

"We chose to discuss the process with the heavy haulage experts at BOOM Logistics," said Mr Chapman.

"They were able to confirm that the proposed process could be carried out ... and, importantly, they had the equipment to do the job," he added.

"The process was a push, pull, carry and lift process," said Darren Jones of Mackay depot of BOOM Logistics' Heavy Haulage Division.

"The 205 tonne boom of the reclaimer was sitting on stools at a height, just over 2.4m above ground.

"As can be seen in the accompanying photo, we located our low profile prime mover and float under the far end of the boom ... and we could do that as the prime mover adapted from a CLR Mack chassis and powered by a 210 hp engine, is only 1.2m in overall height.

"Then, with a lift mechanism on our float, we were able to lift the reclaimer's boom up off the stands with the 125 tonne weight of that end of the boom then carried by the float," explained Darren.

The crew were then able to bring in the big full size 550 hp Mack Titan prime mover with a specially engineered front mounted drawbar and connect it to the float.

With the other end of the reclaimer's boom to be lifted by a Manitowoc 200 tonne ringer crane, all was ready for the lift and shift.

First, the end of the boom to be lifted by the ringer crane was raised 12 m, being the final height for attaching to the slew deck of the reclaimer, before the moving process commenced.

The crane, with the load suspended, was in free slew mode, so the reclaimer boom could be moved forward towards the machine.

"With ringer crane holding up the reclaimer's boom, as well as slewing its own boom and the low profile prime mover - aided by the push from the big Mack - we were able to move forward, 1m at a time.

"Then, as we neared the machine, extreme care was exercised. The reclaimer's boom was inched into position for attaching to the mounting point. Absolute precision was required in order to insert the 180 kg pins through the bearings in the boom," added Darren.

With this process, using BOOM's heavy haulage equipment and crew, ThyssenKrupp were able to make considerable savings and more importantly, reduce the risk of working at height, when compared with the earlier technique of fitting out the reclaimer boom when it was located 'up in the air' nearer its working position and attached to the machine.

First saving was the need for only one large crane, in lieu of two.

Second saving was eliminating many working at height issues.

And third saving was completing the job in far shorter time ... approximately six weeks shorter.

That translates to far less waiting time for the huge fleet of coal carrying ships anchored off hay Point, all at a huge cost.

Low profile prime mover

Pictured is the worksite just before the
'lift and shift' process for the big boom
of the Bucket Wheel Reclaimer.

BOOM Logistics' green low profile prime
mover is just visible, tucked in under
the boom. The big Mack pusher truck is
ready to push and the 200 tonne pin
jib crawler, taking the weight, is ready
to being the boom up and towards the
mounting point of the machine.

Innovative lift and shift for big bucket wheel reclaimer saves time.

© 2008 BOOM Logistics Australia
Home l Company Overview l Range of lifting & access equipment l Heavy haulage l Interesting crane lifts l Employment opportunities
Investor relations l Links l Locations l Low profile prime movers l News l Services l Industry sectors l Fleet overview l Contact