Enerpac 1000 Tonne Jack-Up for Collett Turbine and Generator Lift
Collett & Sons have completed their first project utilising an Enerpac JS-250 Jack-Up system.
Installing a 100 Tonne Siemens steam turbine SST-600 and 60 Tonne generator at a new incinerator plant in Hull, UK. Working within tight space restrictions, the four tower Jack-Up system lifted the power generation plant equipment to a height of 4.5m, allowing it to be easily skidded into position.
The Enerpac JS-250 Jack-Up system is a 1000 Tonne capacity multi-point, synchronous lifting system with self-contained hydraulics in each unit for uncluttered work areas. Loads are lifted in increments as steel “barrels” are stacked together to form lifting towers. Utilising Collett’s SPMT capabilities, the 100 Tonne Siemens steam turbine and the 60 Tonne generator were manoeuvred on site within the plant and positioned above the Jack-Up units at each corner of the load. Following the 4.5m lift, Collett’s skidding systems allowed for both the generator and the steam turbine to be skidded for 14m into final position.
“The Enerpac Jack-Up system is perfect for this kind of job,” says Lincoln Collett, Technical Director, Collet & Sons Ltd. “We considered a gantry, but there was no space to move the gantry forward to position the turbine and generator. The combination of the Jack-Up’s synchronised lift and skidding worked very well.”
The Enerpac Jack-Up system is manufactured at Enerpac Heavy Lifting Technology in Hengelo, The Netherlands and compliments Collett’s already wide-ranging heavy lift offering. Collett & Sons established hydraulic jacking & skidding services facilitate the manoeuvring, positioning, extraction and relocation of cargoes in confined spaces, and by employing the JS-250 new Jack-Up system allows them to offer an innovative solution for undertaking these movements at height.
ISO 9001:2015, 14001:2015 & 18001:2007 Accreditation
Collett are delighted to announce that we have received accreditation to the new 9001:2015 Quality Management System, the new 14001:2015 Environmental Management System and the existing OHSAS 18001:2007.
We are one of the first companies in the heavy lifting and heavy haulage sector to achieve certification to the new 9001:2015 Quality Management System, the new 14001:2015 Environmental Management System and the existing OHSAS 18001:2007 Occupational Health and Safety Management System, by the UKAS Accredited British Assessment Bureau. The 2015 versions of the standards replace the previous versions, that become obsolete in September 2018.
Delivering Galloper Onshore Substation
With the development of Galloper Offshore Wind Farm underway, an extension of the fully operational Greater Gabbard Wind Farm off the coast of Suffolk, Collett were tasked with providing transport logistics for a 180Tonne Transformer destined for the onshore substation.
Originating in South Korea the Super Grid Transformer, which measures an impressive 8.7m (L) x 4.9, (W) x 4.7m (H) was scheduled to arrive at the Port of Lowestoft via Rotterdam in late September. With the instruction of the project, on behalf of Hemisphere Freight Services, beginning in June this provided a tight four month timescale in which plan, execute and complete the delivery.
Working closely with Hemisphere Freight Services Ltd and Robert Wynn & Sons, a solution for transferring the transformer from the originating vessel at Rotterdam to the specialist RoRo barge, the Terra Marique was devised. In collaboration Collett, Hemisphere and Wynns engineered specialist calculations and technical drawings of the loaded cargo to confirm the transformer’s stability and safety whilst on board the vessel. On arrival in Lowestoft the vessel’s hydraulic roadway would provide the option of delivering onto varying quay heights enabling the approach during high tide.
Once in Lowestoft the next challenge would be to transport the cargo the 27 mile journey from portside to delivery site. With the transformer loaded to our specialist girder bridge for the journey the entire combination would feature 20 axles, two tractor units in push pull formation and an overall length of 70.5m which would require the route to be scrutinised in meticulous detail to ensure safe passage. The proposed route navigated the towns and villages of Lowestoft, Kessingland, Wrentham, Wangford, Blythburgh and Yoxford and as a result would require intricate planning and surveying to ensure the safe passage of the 70.5 (L) x 5.3 (W) x 4.8 (H) loaded vehicle.
Undertaking a Visual Route Inspection two months ahead of the proposed transport date, Collett’s Projects Division surveyed the route in detail and identified several modifications which would be required to enable the loaded girder bridge to safely travel to its required destination. This included the removal street signage, traffic lights and the trimming of foliage to guarantee the vehicle would over sail the landscape.
As the deadline for the transformer’s arrival grew ever closer Collett’s meticulous planning ensured the seamless delivery of the project. Having undertaken Visual Route Inspections, Swept Path Analysis reports, Lifting Plans, Transport Arrangements and Jacking & Skidding Calculations our Teams had all bases covered and we were ready to begin.
In late September the vessel arrived at the Belvedere Quay where the awaiting Collett Team set to discharging the cargo.
Utilising a 10 axle SPMT with hydraulic capabilities Collett boarded the Terra Marique to self-load the 180Tonne transformer from its secured position within the hold of the barge. As the vessel dropped the hydraulic roadway Collett manoeuvred the cargo portside where it was positioned on stools to allow for assembly of the girder bridge. The loaded combination then remained portside ready for onward transport.
At 8:30am on Saturday 1st October the convoy began its journey. Travelling under BE16 permit, and with both police and private escorts, the Collett Team left the Port of Lowestoft and began the pre-planned journey. Destined for Leiston the combination navigated country roads, several roundabouts and traversed two level crossings all at a maximum speed of 12mph throughout. With onlookers lining the streets keen to capture a glimpse of such a heavy transport project in progress the convoy meandered its way along the route arriving seven hours and several villages later on approach to the site entrance. Having completed stringent height checks to ensure the loaded vehicle did not exceed the minimum clearance distances for the overhead lines the convoy safely made its way onto the construction site.
Arriving at the substation the final stage of the project began, delivering and positioning the transformer to the awaiting plinth. Throughout the extensive planning of the project our Team also implemented detailed jacking & skidding stress and pressure simulations to analyse the skid track behaviour and stress distribution across the system throughout the movement. Replicating the movement of the transformer across the 400Tonne capacity jacking and skidding system allowed our Team to check pressure, stresses and deformations across the track to ensure maximum safety. With the jacking and skidding system already on site we began the task of unloading the transformer from the girder bridge ready for positioning. Collett’s Heavy Lift Team gradually manoeuvred the transformer to the awaiting plinth before aligning and jacking & skidding to its final position.
Throughout the planning and execution of the project our Teams liaised directly with Hemisphere Freight Services, local councils and constabularies, Network Rail and marine transport specialists Robert Wynn & Sons to ensure the seamless delivery of the project from start to finish.
140 Tonnes from Kilnhurst to Immingham
With 140 Tonnes of deaerator vessel destined for Immingham Dock, South Yorkshire’s Charles Thompson Ltd appointed Collett & Sons to facilitate the route planning, transport and port agency services for the cumbersome 28m long cargo.
European Hauliers Form the Route To Space Alliance
Five highly established hauliers from across Europe have joined together to offer a bespoke transport and logistics service specifically tailored to the aerospace, astrospace and research laboratory industries.
French company Chabrillac, UK based Collett Group, Switzerland’s Friderici Spécial and German companies Hermann Paule and WeiLa Transport have united to form the Route To Space Alliance.
The Alliance, which headquarters in Toulouse, offers the collective experience, knowledge and skills of all five members providing a complete transport service for highly sensitive, unique and irreplaceable items. All five hauliers are family firms recognised for their reliability, and possess years of experience in transporting high technology products and abnormal loads.
Speaking on the birth of the Alliance, President and Managing Director of Chabrillac, Jérôme Pasdeloup states, “Our clients consider us as a very reliable transport company with strong commitments and schedules, perfectly adapted to their needs and with local facilities. From offering this service to our European clients across France we identified an opportunity to offer these specialist services at a European level.”
Born out of a desire to provide a dedicated logistics service for sensitive, delicate and highly valuable cargoes, the collaboration of these five companies delivers a bespoke service for the high technology industries.
“Firstly discussing with our German partners, then with a Swiss and an English partner, who are all highly experienced in the specialist logistics sector, the Route To Space Alliance became a reality.” Jérôme continues, “By forming this Alliance we have successfully brought together our years of experience, our companies’ skill, facilities and knowledge, allowing us to offer a dedicated service for specialist cargoes across Europe.”
The Route To Space Alliance is represented across 13 sites in four countries and features 185.000m2 of depot space, 45.050m2 of warehousing, over 500 employees and over 700 specialist vehicles, trailers and SPMTs.
For more information about the five hauliers and the project's they've undertaken please take a look at the Route To Space website.
Littlebrook on the Move
Following a similar successful operation in 2014 which required the relocation of six transformers, Collett were once again approached by Drax Power Ltd, this time to facilitate the relocation of nine 185Tonne transformers as a result of Littlebrook Power Station D’s closure in March 2015.
The project called upon the expertise of Collett to devise a solution for transporting each of the transformers, measuring 5.08m (H) x 3.5m (W) x 6.5m (L), from Dartford to Drax Power Station near Selby, North Yorkshire. Faced with the task of moving several abnormal loads originating within the busy capital the Collett Team began devising intricate transport arrangements to facilitate the loads.
It was proposed that each of the loads would be moved in three stages. Firstly each transformer would be transported individually from Littlebrook to Thamesport, Isle of Grain where the loads would be consolidated into two RoRo barge shipments delivered directly to the Port of Goole. From here the transformers would be stored at Collett’s Goole Heavy Lift Terminal prior to the final 5 mile onward transport to Drax Power Station.
This proposal required intricate planning throughout; however the logistics of transporting these heavy cargoes from Littlebrook to Thamesport would provide the biggest challenge. Collett’s Consulting Division worked tirelessly undertaking route studies, site visits and swept path analysis reports of several roads and surroundings to ensure a safe suitable path for the movements. Having liaised with local authorities, councils and constabularies an agreed route was firmly in place and in March Collett mobilised their fleet and headed for Littlebrook Power station to begin the first of the transformer moves.
Not a simple task of lifting each transformer and loading to an awaiting trailer, each transformer, due to its position, required complex manoeuvring procedures to allow Collett’s Team to safely position for transport.
Due to the position of the transformers Collett had to utilise their specialist heavy duty Jacking & Skidding system to manoeuvre each of the cargoes. Space limitations within Littlebrook required each transformer to be skidded 6m, before turning 90 degrees and skidding a further 18m to safely clear the confines of the power station’s industrial surroundings. Finally, after Jacking & Skidding from their original position, the transformers were turned a further 90 degrees to position for loading.
Utilising Collett’s Girder Bridge for the initial stage of the project the first transformer was loaded to the trailer and at 9pm the convoy began its 24 mile journey. Travelling with three tractor units, two in push pull formation and one in support, four police escorts and two pilot cars, the convoy left Littlebrook Power Station. As identified by Collett’s Consulting Team the combination, due to its overall loaded weight of 390Te, 16Te per axle and substantial 71m (L) & 5.13M (W) loaded dimensions, would be unable to use the bridge over the M25 at Littlebrook Interchange, and as a result, a rolling road block had been put into place on both the northbound and southbound carriageways of the M25. This allowed the entire Girder Bridge to contraflow two roundabouts and utilise the northbound sliproad to gain access to the M25. Once on the motorway Collett’s Team reversed the entire combination for half a mile across the central reservation and along the southbound carriageway allowing access to Exit 1A and onward transport to Thamesport.
Once this intricate manoeuvre was complete the convoy continued enroute, employing extensive traffic management throughout as the Collett Team navigated 4-lane motorways, dual and single carriageways. Having negotiated 18 roundabouts, undertaken several contraflow manoeuvres, implemented Temporary Traffic Restriction Orders and employed manual steering practices at select points along the route, approximately 6 hours after departing from Littlebrook Power Station the transformer arrived safely at Thamesport.
Over the following weeks the remaining transformers left Littlebrook and were safely consolidated at Thamesport and after discharge from the Girder Bridge each transformer was stored on stools and load spreading mats portside. With the transformers safely stored at the Port Collett chartered the Terra Marique RoRo barge, featuring a hydraulic roadway and ballast system allowing for the vessel to load on varying quay heights. The Collett Team set to loading each of the transformers to SPMT and conventional axles and expertly manoeuvred each one to the hull of the vessel. With the loads safely secured the barge set sail for Goole, firstly carrying three transformers with a second shipment of six to follow in the coming weeks.
With the loads arriving safely in Goole Collett began work discharging the transformers once again utilising SPMT operations and conventional axles to unload the transformers at the Port. Each transformer then made the short journey to the Collett’s Goole Heavy Lift Facility for storage on stools for ease of re-loading.
As and when required each transformer left Collett’s Goole Depot and travelled the short distance to Drax Power Station where, once again utilising specialist Jacking & Skidding systems, each transformer was carefully manoeuvred into position for storage.
With a total of 9 Girder Bridge movements, two RoRo Barge shipments, nine onward transportation operations and numerous Jacking & Skidding manoeuvres this project certainly provided a challenge that the entire Collett Team expertly rose to, completing each stage to the highest of standards.
Central London with 87 Tonnes
It’s been a busy weekend for the Collett Team as we hit the road and headed to the Capital with 87Tonnes of steel plate girder from specialist structural steel fabricators, William Hare.
Destined for the 22 Bishopsgate construction site the 16.26m long cargo was required to travel from William Hare’s North East fabrication facilities, via a coating facility in Middlesbrough, to final destination deep within Central London’s bustling streets. Not a straightforward transport project, this required significant logistical planning to deliver a load of this weight and size directly into the heart of the capital.
The Plate Girder would be moved in 2 stages. Initially the load would be transported from the North East fabrication site across to Middlesbrough for painting which would require the use of a 12 row modular trailer. Once painted the load would then make the final stage of its journey from Middlesbrough to Bishopsgate.
Months before any wheels began to roll Collett’s Consulting Team began the planning of the movement, identifying a suitable route for the project and undertaking site visits, route access surveys and detailed swept path analysis reports to ensure the load and trailer could safely traverse the route.
With a plan firmly in place and having completed the stage from William Hare to Middlesbrough the girder plate was loaded to Collett’s 14 row modular trailer and on Friday morning we set off for London.
After stopping overnight at Toddington Services, early Saturday morning we were joined by Hertfordshire Police who escorted the load around a diversion route in the Watford area. A weight limit had been put in place on the M25 which applied to all abnormal loads over 44 Tonnes and with our 87 Tonne load we were required to follow this alternative route. The loaded vehicle then proceeded from M25 junction 19 with our own escort to the abnormal load lay by on the A312 just south of the M4 at junction 3.
The final leg of the journey took place in the early hours of Sunday morning to avoid as much disruption as possible on the city’s streets and as the majority of London slept, our Team prepared to set off. At 4am, accompanied by Collett’s Escort Vehicles, Metropolitan Police and City of London Police, the 16.26m (L) x 2.3m (W) x3.56m (H) cargo began its journey.
Our early morning sightseeing tour took us via Hammersmith, Knightsbridge, Hyde Park Corner, Horseferry Road, Parliament Square, Trafalgar Square, Fleet Street, St Paul’s Cathedral and onwards to Bishopsgate as we meandered through the city’s streets employing manual steering, contraflow manoeuvres and traffic management operations throughout.
On arrival at the junction between Wormwood Street and the A10 Bishopsgate, our earlier swept path analysis reports had identified a reverse manoeuvre, which would have to be undertaken to allow the vehicle to negotiate this junction and complete the journey. Due to the total loaded length of 33.134m our Team had to manoeuvre the entire combination directly across the junction before reversing onto the North side of the carriageway, this would then allow the vehicle to continue Southbound on the A10 towards its final destination. Once again employing manual steering and traffic management from Collett’s Escort Vehicles and the accompanying Police representatives, the repositioning operations were carried out and the load could continue onwards to 22 Bishopsgate.
Buccaneer on the Move
This project, for BAE Systems involved the relocation of a 1960’s Blackburn Buccaneer XV168 from its position as Gate Guard on their Brough site to Elvington Airfield.
The Buccaneer was the last true Blackburn aircraft to be designed and constructed at the then British Aerospace site, and became the company’s most successful and longest serving type with 35 years of service.
Undertaking several site visits ahead of the move, the Collett Team took extra care in planning the relocation as not only did the cargo have historical significance, but was also a dedicated memorial to four test pilots who gave their lives in the development and testing of the Buccaneer type.
Having been on site in Brough for 20 years, the first and last Buccaneer to ever land at Brough Airfield, the delicate operation required meticulous planning from beginning to end. Enlisting the assistance of the Buccaneer Aviation Group, an organisation of volunteers who are dedicated to the preservation and maintenance of Royal Air Force Buccaneer aircraft, we devised the ideal solution for lifting, securing and transporting the 14 Tonne load.
The nature of the load provided several hurdles when planning the transportation, the curved underside of the aircraft, the wheels and of course the wingspan of this impressive cargo all had to be taken into consideration. Added to this, the tricky right turn from the BAE site, the immediate route through the residential streets and the Police Escorts required across Humberside and North Yorkshire.
The 19.3m load necessitated a specialist trailer from the fleet and with over 100 trailers at our disposal, one unique trailer identified itself as perfect for the job. A 19m long extendable beam low loader, hydraulically extendable width ways was the perfect solution to assist in the safe load support and lashing.
Securing the aircraft was the first hurdle, the wheels and curved underside of the aircraft proved awkward when planning to secure the load to the trailer, therefore, a solution was proposed in which the wheels would be folded away and bomb doors of the aircraft would be slid open, thus providing the team with a steady base on which to transport the cargo. The 44ft wingspan of the Buccaneer became the next hurdle. Liaising directly with the Yorkshire Air Museum and the Buccaneer Aviation Group, it was proposed that the wings would be folded upwards and secured, reducing the width of the load to 6.05m allowing for safe passage through the streets but also requiring a VR1 Permit for transportation.
On the day of the move, crowds of spectators lined the residential route through Brough, eager to see the Buccaneer en-route to its new home. At 10am the combination began its journey under Police Escort. Unable to make the right turn from the BAE Systems site, the vehicle and trailer combination reversed out of the site and faced a much easier left turn on to Skillings Lane, through Brough and eventually joining the A63 motorway. Travelling the wrong way around a roundabout on the Stockbridge Road, the 3 axle low loader and 4 axle tractor remained under Police Escort throughout its entire trip, firstly by Humberside Police to Selby and then by North Yorkshire Police from Selby onwards to Elvington.
The Buccaneer arrived safely at the Yorkshire Air Museum to be greeted by awaiting Museum staff eager to add this historic piece to their collection. With access no issue at Elvington Airfield, the load was delivered to the Museum, and lifted from the trailer to its new pad location within the Museum’s grounds.
Mindful that the aircraft was also a memorial to those four test pilots, the Museum organised a re-dedication ceremony in honour of the crew.
Collett Set Sail for the Caribbean
It’s not everyday you get asked to go on a trip to the Caribbean, especially not carrying two 89Tonne diesel engines, but the Collett Team aren’t afraid of a challenge!
The project required the shipment and delivery of two diesel engines and six boilers to the Lowmans Bay Power Plant on the island of St Vincent in the Caribbean. Once on the island, transportation from the Port of Campden Park Bay was only a short distance of 2.1km but due to the size and weight of the loads the expertise of Collett was called upon to facilitate the project.
The planning began months ahead of the move, after all we were undertaking a job at the other side of the world and every detail had to be meticulously scrutinised to ensure a smooth operation from beginning to end.
The loads were situated at separate manufacturing points therefore the Collett Team organised for the consolidation of the entire shipment at the Port of Hamburg. Once all loads were consolidated at port the diesel engines and the four boilers were loaded to the geared vessel chartered by Collett and she set sail for the crystal clear waters of the Caribbean. Travelling in the same vessel, Collett’s ten axle Scheuerle Self Propelled Modular Transporter (SPMT) and Power Pack, ready to accept the loads and deliver to Lowmans Bay Power Plant.
Arriving safely in the Caribbean, all six loads were successfully offloaded one by one prepared for transportation in sequence.
Having already undertaken a site visit and assessed the suitability of the proposed route Collett’s Team had liaised with local authorities and organised cable lifting teams to ensure safe passage for the SPMT and its cargo. The next hurdle came in the form of a small bridge in the village of Campden Park. Identified during the planning stages by the Collett Team, the bridge was structurally intact but would require additional support to allow safe passage. Ahead of the move, the team had braced the bridge which would provide sufficient support to prevent compromising the cargo, the SPMTs and avoid any damage to the bridge itself.
Once the team had navigated the narrow bridge the loads continued en-route, arriving safe and sound at the power station ready to be manoeuvred into position. Delivering directly into the power station building, the engines were unloaded from the SPMTs and positioned in place on pre-installed support beams via Collett’s Jacking & Skidding system.
Once both diesel engines were in position, the Collett Team enjoyed a well-deserved drink in the Caribbean sun before packing up the SMPT and heading back to Halifax, another job well done!
Jacking & Skidding from Leeds to Kent
Collett’s new Jacking & Skidding system proved a shrewd investment as it was called upon to facilitate the move of a 50T transformer on behalf of Wilsons Power Solutions.
The 45/50 MVA power transformer was destined for Owls Hatch Solar Farm and with the deadline for delivery approaching the Collett Team were called upon to deliver the cargo to its foundation site.
Arriving on site in Leeds, David Christy and the Heavy Lift Team set to work.
Utilising the new system, four 25T jacks were placed at designated jacking points under the transformer, once all safely in place the jacks were put to work gradually raising the load in 25cm increments. Slowly the transformer rose from its position, supported throughout by timber safety packing the team continued to raise the transformer to a suitable height which would allow the installation of the skidding system.
Once at the optimum height, it was the turn of the modular skidding system to be installed. After carefully placing the tracks under the load, the skidding system was then fitted with the hydraulic push-pull units and low-friction skidding pads. As the push-pull units hydraulically extended and retracted between the locking points on the track, the 50T load moved effortlessly from its location, gliding towards the awaiting trailer bed which had been lowered to ground level in anticipation of the cargo.
Having been skated directly into position on the trailer, the jacking system was re-introduced to lift the load and allow for the removal of the skiding system. With the skidding system removed and the load safely secured on the trailer the Collett Team set off for their Goole depot where the transformer would be stored overnight.
Bright and early the following morning the Team were on site at Goole and ready to go. Having organised the necessary permits for the transport and notified all the relevant authorities, the transformer set off for its final destination, Owls Hatch Solar Farm in Kent.
Once on site, the Jacking & Skidding systems were utilised once again, effortlessly lifting and sliding the load from the trailer bed directly to its foundation site. With the transformer in place Collett’s job was done, Owls Hatch had taken delivery of their transformer and the development could enter its next phase.
The solar farm, which will spread across 8 fields, once complete will be one of the largest solar farms in the UK.
Transforming Burbo Bank Wind Farm
Collett’s Girder Bridge Trailer is called into action once again, this time to facilitate the delivery of two 200Te transformers destined for the onshore substation at Burbo Bank.
With construction underway on Burbo Bank Extension, DONG Energy required the delivery and installation of two 200Te transformers at their onshore substation. Once constructed, the substation will allow the 32 turbine offshore wind farm to connect to the national grid and begin generating power for over 180,000 homes.
Handling delivery of the transformers into the UK, SDV UK Ltd called upon the expertise of Collett to facilitate the ship’s discharge at the Port of Mostyn and the following transport to site of the two cumbersome cargoes. With the ship arriving in July the team were onsite to undertake the project with two ballast tractors and a 14 axle modular hydraulic flat top trailer.
Having already undertaken the required planning for discharging the vessel the Collett Heavy Lift Team, operating under CPA Contract Lift conditions, began the task of unloading the components from the hull of the ship utilising a 750Te crane. Each load was lifted from the ship and delivered to the awaiting 14 axle trailer. The loads were then transported to an agreed holding position at the port where they were stored on stools until a suitable construction stage at the substation allowed for delivery.
The delivery of the two loads took place in September, but due to the size and weight of the transformers this was no-where near an everyday undertaking. Each transformer measured 11,400mm (L) x4,400mm (W) x 4,750mm (H) and weighed 200Te, therefore a more specialist method of delivery had to be devised to facilitate the loads owing to height and structure restrictions en-route.
In order to utilize the abnormal load exit at the Port of Mostyn, the loads were required to travel over a level crossing. Usually this wouldn’t be an issue, however due to the weight of the loads and the size of the rail track Collett were required to obtain official track possession. This allowed the two transformers to travel over the level crossing on modular trailers. The loads would then be positioned in a local layby, approximately one mile from the Port, for transhipment from the 12 axle flat top to the 550Te capacity Girder Bridge for onward transportation. Not a simple task of lifting from one to the other, the loads once again had to be positioned on stools whilst the Collett Team took to building the modular Girder Bridge around the load.
Once constructed, the overall dimensions of the combination and load required specialist route planning from the Collett Consulting Team, providing Traffic Management Plans and route analysis ahead of the project to ensure a safe delivery. This required the team to pore over mapping data for several days, intricately planning the route to prove suitability, undertaking Swept Path Analysis and conventional surveying techniques to plan the project to perfection.
The final route plan highlighted a weak bridge, too fragile to accommodate the Girder Bridge and load, consequently the team obtained a temporary traffic restriction order, which required a 12 week approval process. This then allowed Collett to contraflow the A55 dual carriageway in the wrong direction, therefore avoiding the bridge and allowing the combination to re-enter the A55 in the correct direction.
Travelling under police escort Collett’s 10 man team departed from the Mostyn layby one late evening in September. Travelling throughout the night the Girder Bridge and its load passed along the rural roads of Flint before joining the A55 for the 15 mile journey to site in St Asaph arriving just as the sun began to rise.
Once on site the team unloaded the transformer and utilizing our Jacking & Hydraulic Skidding system manoeuvred it into position onto a plinth and aligned onto anti vibration pads. Fast forward five days and following the exact same procedure, the second transformer was collected from the layby and delivered to site.
The collaboration between Collett’s Consulting, Projects and Heavy Lift Divisions provided invaluable in planning and undertaking the delivery of these two cargoes. Liaising with Network Rail, North Wales Police and the councils of both Flint and Denbighshire ensured a faultless delivery from port to site and positive feedback from all involved.
Bridging the Gap for the Hoobrook Link Road
The Collett Team have been on site in Kidderminster, helping to deliver phase 2 of the Hoobrook Link Road Development.
The development, which when completed will connect the A451 Stourport Road through to the A442 Worcester Road, required the delivery of several steel beams to form a bridge over the Staffordshire and Worcestershire Canal and the Stour River.
The bridge components consisted of six sections measuring between 15.5m and 27.8m long, which once on site in Kidderminster would be used to construct the complete bridge structure. However, the first phase of the project involved transporting the beams under escort from their point of manufacture at Allerton Steel in Northallerton the short distance to Middlesbrough for shot blasting.
In mid-November our team took to the road once again, collecting the beams from Middlesbrough for onward delivery to site in Kidderminster. Again travelling under escort and with all the required permits and notifications in place, the beams left Middlesbrough and arrived safely on site.
Once all deliveries were completed the six beams were amalgamated to form two 160 Tonne sections, each measuring an impressive 58m long. These two sections would then form the new bridge, although, due to the layout of the delivery site, the bridge sections had to be constructed at the top of a hill close to the river. This required some expert planning from the Collett Team to facilitate delivery to the river side. Although only a short distance the challenge of transporting such lengthy cargoes down a progressive incline certainly posed a logistical challenge.
Having undertaken several site visits and with a firm plan in place we mobilised the fleet, setting off for Kidderminster with two ballast tractors, two 8 axle bogie trailers complete with turntables and a power booster module.
One early December morning our team set to work, loading the first section from its position on stools at the top of the hill. Due to the gradient of the incline, our team very carefully manoeuvred the load down the hill towards the river, utilising the hydraulic capabilities of the bogie trailers and turntables to ensure that the lengthy cargo remained stable during the descent. With the power booster attached to the bogie trailer at the front of the combination and a ballast tractor at the rear, the bridge section descended the slope, arriving safely to the river side directly under the hook of an awaiting 750Te crane complete with Super lift.
Under the watchful eye of local media, contractors and councillors, the bridge section was secured to the crane and hoisted over the river, one down, one to go. After a well-earned tea break our team headed back up the hill ready to tackle the second bridge section. Following the exact same procedure we loaded the second bridge section to the trailers and set off down the hill. By mid-afternoon the second section arrived alongside the crane ready for lifting the following morning. Another job expertly completed by the Collett Team!
Working closely with specialist structural fabrication manufacturers, Allerton Steel and leading civil engineering project contractors Alun Griffiths throughout, Collett provided logistical transport solutions for each stage of the project from point of manufacture to final delivery on site.
The building of the bridge marks a key milestone in the Hoobrook Link Road Project, due for completion in Summer 2016, the Link Road will provide improved access, connect two key employment corridors, promote much needed economic growth and relieve traffic congestion.
The UK’s Largest Onshore Turbine Blades, Delivered!
Some would shy away from the challenge of transporting three 145m wind turbines featuring 58.7m blades, we say bring it on!
With approval granted for the phase three of Muirhall Wind Farm in South Lanarkshire Collett were called upon to facilitate the import and delivery of eighteen components from the Port of Grangemouth, components which when constructed would form three GE 2.75-120 145m wind turbines.
Having delivered two Senvion turbines for phase two of the Muirhall extension in February 2014, the previous holders of the largest onshore turbine blade record, we were well practiced at traversing the route from Port to pad side with the turbine component cargoes. However, due to the massive 58.7m length of the phase three blades, and the massive 63.35m overall loaded length, our teams had to undertake meticulous planning ahead of the project. To ensure suitability of the route Collett Consulting pored over data providing Swept Path Analysis Reports and Route Access Surveys before undertaking a Test Drive of the route with a vehicle adapted to accurately reflect the loaded vehicle dimensions. The provision of all this data identified several requirements along the route to enable the convoy’s safe passage, this included street furniture removal, relocation of signage and lamp posts, pruning of foliage, third party land requirements and certain sections where the placing of track way would be necessary. The tower sections would move freely along the route but these special measures were essential for safe delivery of the blades. After liaising with several authorities, highways departments and constabularies the route was agreed and adapted to accommodate the convoy, now all we needed were the turbines themselves.
Cue the arrival of the ships. Handled by Collett’s Marine Division, two vessels were expected at the Port of Grangemouth, the first arriving from Poland carrying the nine turbine blades, the second from Turkey carrying the nine tower sections. As the vessel’s arrived our teams were on hand Portside ready to begin the discharging of the ships. One by one each of the components were safely lifted from the vessel to an agreed laydown plan portside at our Grangemouth Heavy Lift Storage Facility. Utilising our 110Te straddle carrier and various cranage equipment, each component was strategically positioned to allow for ease of loading in line with the delivery schedule. Here the loads would remain until the stage of construction at Muirhall could facilitate delivery allowing Collett to provide a Just in Time service.
The hubs and nacelles for each turbine were located in Germany. This provided yet another logistical challenge requiring expert co-ordination from our teams to ensure an orchestrated arrival of the components necessary for each complete turbine. Our teams once again rose to the challenge, with expert logistical planning and execution Collett ensured that deliveries of these integral components fell in line with the agreed schedule.
As the end of November approached the first delivery to site set off. In order to minimise disruption, and due to the size of the cargoes and the route they would be travelling, each convoy consisted of one tower section and one turbine blade. Accompanied by Collett’s Pilot Vehicles and under Police Escort the convoy made its way along the route, manoeuvring the components through the villages of South Lanarkshire with our expert drivers effortlessly taking the challenging route in their stride. After crossing splitter islands, employing contraflow manoeuvres and utilising manual steering at key points throughout the route all components arrived safely on site ready for construction.
Working on a 6 day a week delivery schedule, and adopting the blade and tower delivery combination, each component safely made the journey from Grangemouth to site, arriving in synchronisation with the construction schedule.
Working closely with the experienced Muirhall Wind Energy Team on both this and the previous phase two extension allowed our team to provide expert logistics throughout. From coordinating the arrival of components from three separate locations across Europe to the extensive planning and execution of manoeuvring a 63.35m loaded combination, our team rose to the challenge and we’re proud to say that we’ve delivered the largest onshore turbine blade in the UK.
Muirhall Wind Farm phase 3 extension, also known as Muirhall South is expected to be operational in March 2016 and will offset circa 10,848 tonnes of CO2 per annum whilst supplying up to 5,773 homes with electricity over the 25 year lifetime.