The recently opened Crown Casino in Sydney has become the tallest building in the city at 271 metres and 75 floors in height. A construction project of this scale and complexity presented a number of vertical access challenges which could not be solved with standard hoists and components.
Alimak was able to draw on the strength and depth of an extensive product range, in addition to several project specific customisations, to successfully address a range of competing vertical access challenges.
The curving form of the tower structure itself made standard vertical access systems unworkable. Alimak’s experienced engineering team was able to develop bespoke hoist cars and ties and ensured they were designed, fabricated and installed to provide for safe and reliable transport of personnel and materials up to 270 metres in height. The large footprint of the construction site and the scale of the building meant that the efficient transport of key people, materials, tools and vehicles was paramount in keeping the project running to schedule. A total of seven Alimak construction hoists were provided to fulfil the varied needs of the project, with the flexibility of a hire agreement meaning superior functionality was achieved in an economical package.
Among the construction hoists deployed was an Alimak Mammoth 55/50, designed to carry up to 5,500 kg. With increased car dimensions, this was ideal for transporting vital heavy equipment such as forklifts and electric pallet jacks to the higher levels, even being able to transport multiple forklifts at once.
Speed and maximising productivity were also key considerations. A combination of hoists with large cars and speeds of up to 80 metres per minute and convenient access points were intelligently deployed to provide for the most efficient deployment of people and materials across the site and to the top levels of the tower. A central core hoist was installed to provide access to the jump form while the building was being topped up.
Alimak has earnt a strong reputation within the construction industry as a leading provider of vertical access solutions with a proven track record of supplying significant high-rise construction projects. The complexity of the Crown Casino project required proven capability, engineering detail and quality machinery which Alimak are famous for.
Location: Crown Casino, Sydney, Australia
Application: High-rise construction
No. of hoist cars: 7
Hoist types: Alimak Scando 650 31/39, Alimak Scando 450 14/24 dual, Alimak Scando 650 32/39, Alimak Scando 650 XL 26/50, Alimak Mammoth 55/50
Capacity/hoist car: Varies between 1,400 kg – 5,500 kg
Speed: Varies between 32 – 80 m/min.
Lifting height: 31m, 72m, 262m
Alimak’s long record of excellence as a leading provider of vertical access solutions for the construction industry was called upon to deliver a reliable and robust construction hoist system for the ambitious project site at Australia 108.
Located in Southbank, Melbourne, this is the tallest residential building in the Southern Hemisphere.
At 319 metres and 100 floors, the efficient transport of key personnel and a broad range of tools, materials and equipment would be vital to realising this bold vision and enhancing safety on site. A particular challenge during this project was the planning and execution of a high capacity construction hoist system which would call for a staged handover of the building as each floor was completed and residents took up occupation. As an integral contributor to the success of the building, the flexible rental solution that Alimak provided, encompassed six highly engineered construction hoist cars built on the rack and pinion drive system pioneered by Alimak.
An Alimak Scando 450 is ideal for transporting both passengers and cargo with a maximum payload of 2,000 kg and a top speed of 55 metres per minute. In addition, Twin FC-S and a Twin FC construction hoists were also deployed to satisfy the scale of the build, with the modular design providing the benefit of two construction hoists utilising a single mast.
Again, the capabilities are impressive with the FC-S having a maximum payload capacity of up to 3,200 kg and travelling at up to 100 metres per minute. The system was able to achieve a lifting height of 220 metres with convenient access to 73 landing points.
In addition to the flexibility of the construction hoist system, the project also benefited from the comprehensive rental operations that Alimak are able to provide as the worldwide market leader. Beyond the supply of the equipment, Alimak’s expert team are also on hand to provide a full range of service and support solutions including consultation and training and maintenance support to ensure the ongoing success of continuous operations. This kind of rental arrangement with appropriate support from industry-leading experts can often deliver a cost-effective solution without compromising on functionality by ensuring that the most appropriate vertical access solutions are in place for each stage of the build process with qualified technicians taking care of the installation and dismantling as required.
Location: Australia 108, Melbourne, Australia
Rental period: March 2017 – July 2019
Hoist type: Alimak Scando 450, Twin FC-S and Twin
Capacity: 450 1400kg / Twin FC-S 3100kg / Twin FC 3200kg
450 Car size: 2.3 x 1.4 x 2.0m (speed 40m/min)
Twin FC-S: 2.2 x 1.5 x 3.9m (speed 100 m/min)
Twin FC: 2.2 x 1.5 x 3.9m (speed 54m/min)
Lifting height: 220 m (applies to all hoists)
No. of landings: 73 (applies to all hoists)
Australia’s first Alimak SC-45 industrial rack and pinion lift is installed on Downer’s new state-of-the-art Wingfield Asphalt Plant. Alimak worked closely with Downer, engineering the SC-45 lift to fit the plant’s pre-designed vertical lift shaft.
A ‘FIRST OF ITS KIND’ ASPHALT PLANT
Construction of Downer Infrastructure’s Wingfield Asphalt Manufacturing Facility was completed in June 2013, with the new facility designed to replace two 40-year-old plants nearing the end of their operational lives.
The manufacturing facility is the first of its kind outside of Europe, and marks a new benchmark in asphalt manufacturing in Australia, incorporating the latest recycling and process technology to reduce energy consumption, lower greenhouse gas emissions and reduce Downer’s carbon footprint. Located in Adelaide, South Australia, the new Wingfield plant will have the capacity to produce asphalt mixes with up to 75% reclaimed asphalt pavement material (recycled road).
PROVIDING ACCESS TO THE BATCH PLANT
In August 2013, Alimak completed the installation and commissioning of an Alimak SC-45 industrial rack and pinion lift on the manufacturing facility. Located on the batch plant, the Alimak SC-45 will provide personnel access and materials transport to the 5 levels of the plant structure, reducing crane lifting requirements and improving safety of operations on site.
MEETING PRE-DESIGN REQUIREMENTS
In designing the Wingfield Asphalt plant, Downer enlisted the design capabilities of the Amman Group, a European company specializing in the design and construction of standardized asphalt mixing plants. As the plant structure had been pre-designed to a template, an allowance for only a small 500kg materials-only hoist had been specified into the initial designs.
Alimak’s challenge was to fit an Alimak industrial lift, capable of materials and personnel transport, into the existing lift-shaft design. In doing so, Alimak engineered the lift to meet all structural load calculations provided for the pre-designed 500kg hoist, while ensuring compliance with Australia Lift Standards (AS 1735: Part 9).
A FIRST ALIMAK SC-45 IN AUSTRALIA
To meet these requirements, the Alimak SC-45 industrial lift was selected. As the first SC-45 installed in Australia, the lift was chosen for several reasons:
- A 1300kg capacity would reduce crane requirements during the lifting of replacement parts on the plant;
- A car size of 1.4 m x 2.4 m would accommodate the dimensions of an emergency stretcher, improving site safety and emergency response;
- The flexibility of the SC-45 design allowed it to be easily configured to fit the pre-design requirements and load calculations of the plant.
A ‘VIRTUAL SHAFT’ SYSTEM
Based on a one-size-fits-most-applications design, the Alimak SC-45 is perfectly suited for installation on new plants and retrofitting to existing structures. To meet the structural load calculations of the 500kg materials hoist template, Alimak designed the SC-45 lift ties and fixings so that no more than a 6kn load would be placed on the existing structure.
Alimak used the Wingfield plant’s existing stair tower for the fixing of the mast ties and brackets, while a vertical pipe enabled the lift to be set back from the landings for better access. It is this unique ‘Virtual Shaft’ system that enables the SC-45 lift to be installed quickly, with minimal work required to existing infrastructure.
AN ALL – WEATHER MAINTENANCE ACCESS SOLUTION
While much of Downer’s Wingfield Asphalt Manufacturing Facility is automated, routine maintenance and inspection of equipment is conducted daily. The Alimak SC-45 industrial lift provides a safe means of gaining access to the upper levels of the batch plant in all weather conditions, and reduces crane lifting on site for the movement of replacement parts and equipment.
Location: Wingfield Asphalt Manufacturing Plant, SA, Australia
Product model: ALIMAK SC-45
Application: Asphalt plant, maintenance lift
Capacity: 1300 kg
Car size: 1.4 m x 2.4 m
Speed: 0.6 m/sec
Lifting height: 24m
Alimak is a global market leader and pioneer in the design and manufacture of vertical access solutions for industrial and construction industries. The company provides high quality rack and pinion and traction elevators, construction hoists and work platforms. Alimak has a well-established global sales, service and distribution platform across more than 90 countries with strong market presence. The company has a large global installed base of over 23,000 units which provides unique know-how of all industrial application areas. Alimak was founded in 1948 and employs over 1,200 people across the world. Alimak is part of Alimak Group which is headquartered in Stockholm, Sweden.
An ALIMAK SE-12 industrial rack and pinion elevator installed to provide safe vertical access on the Incitec Fertilizers urea granulation plant in Brisbane, Australia eliminates the need for a conventional elevator shaft.
Originally producing prilled urea, the facility was upgraded in 1999 and now produces 750 tons per day of the large size granular variety that farmers prefer.
Since the facility lies close to residential areas, control of dust and emissions is very important. The plant’s floors are washed down regularly to eliminate dust, creating a flow of waste water that could easily enter an internal elevator shaft. An external elevator was therefore the preferred alternative, and the Alimak elevator supplied by Alimak in Australia provided the ideal solution. Not only is the Alimak elevator less expensive to install than an internal elevator and shaft, it doesn’t take up valuable internal space.
The granulation building includes six externally accessed levels, with up to four internal podium levels. The plant is operational 24 hours a day, seven days a week, and the ALIMAK SE-12 rack and pinion elevator is used as many as 20 times a day by engineering and maintenance staff.
The plant’s ALIMAK SE-elevator travels a total height of 29 metres and has a payload capacity of 1200 kg. The mast is tied to structural steel behind the building’s cladding. Electrically and mechanically interlocked landing doors are built into the walls for safe access to the building’s different levels.
The ALIMAK SE elevator range is ideally suited for industrial environments. It is ruggedly constructed, with extruded aluminium car wall panels, hot-dipped galvanized steel car support frame and mast sections, and stainless-steel electric cabinets and landing control boxes. Its design and modular construction permit up to 30 different car sizes to be configured to meet a wide range of application requirements. Featuring a direct-on-line motor controller or an optional closed-loop variable frequency control for smooth starting and stopping, the ALIMAK SE range offers lifting heights in excess of 250 metres and speeds of 0.4 metres to 1.0 meters per second.
Location: Incitec Fertilisers urea granulation plant, Brisbane, Australia
Application: Granulation building
Elevator type: Rack and pinion
Elevator model: ALIMAK SE-12
Capacity: 1200 kg
Elevator car size: 1.30 m x 2.08 m x 2.17 m (W x L x H)
Lifting height: 29 m
Accessing bridge pylons for service and maintenance presents one of the trickiest challenges for lift and access companies. Alimak rack and pinion lifts adapt to inclinations and curves, tight spaces and windy conditions and climb to the very top of the highest structures.
In 2002, a specially-built Alimak SE 500 passenger lift was commissioned to provide access to one of the best panoramic views of Thailand’s capital. The lift is installed inside the inverted-Y concrete pylon of the prestigious Rama VIII cabled-stay bridge, which crosses the Chao Phraya River in Bangkok. Measuring 0.9 m x 1.3 m, it travels up one of the pylon’s legs at a rate of 1 m/sec. At around 75 m, the lift slows to 0.2 m/sec to adjust for the vertical climb, and then resumes full speed for the remainder of the journey to the observation platform at the top of the 161 m-high pylon. The lift’s U-600 guide rail is curved with an inclination of 13° in the lower section and vertical on the upper section. Alimak achieved this by dividing the main frame into five pieces.
The Rama VIII Bridge is named after Thailand’s former King Rama VIII, and was officially opened in September 2002, the same year that Bangkok celebrated its 220 anniversary. It features a 300 m main span, and has two lanes in each direction for traffic, plus a bicycle and walkway lane.
Other bridge projects Other examples of bridge projects around the world where Alimak industrial lifts or construction hoists have been installed include:
- Viaduc de Millau, France
- Chung Sin, Taiwan
- Pont de Normandie, France
- Sunshine Skyway Bridge, USA
- Second Severn Crossing Bridge, UK
- Honshu Shikoku Bridges, Japan
- Tsing Ma/Ting Kau/Kap Shui Mun Bridges, Hong Kong
- Great Belt Bridge, Denmark
- Øresund Bridge, Sweden-Denmark
- Megyeri Bridge, Budapest, Hungary
Location: Rama VIII Bridge, Bangkok, Thailand
Installation year: 2002
Application: Bridge pylon
Elevator type: Rack and Pinion
Elevator model: Alimak SE 500 SP
Capacity: 500 kg
Elevator car size: 0.91 m x 1.3 m (W x L)
Speed: 1.0/0.2 m/s
Lifting height: 151.4 m
No. of landings: 2
A temporary Alimak rack and pinion hoist was installed at the petroleum refinery, providing access to the Reformer Tower during plant shutdown and refurbishment. Alimak worked in compliance with all site safety regulations, operating conditions and timeframes.
An Alimak Scando rack and pinion construction hoist was installed at the petroleum refinery for use during the shutdown, refurbishment and reconditioning of the hydrogen production unit, known as the Reformer BHU. Given the highly flammable environment of the petro-chemical plant, and the nature of the products produced, strict safety and operating conditions were enforced on site. Working within facility requirements, Alimak provided a temporary access solution that allowed shutdown work to be completed within the designated timeframe.
Providing access to the Reformer tower
In order to complete necessary maintenance and upgrades to the facility on schedule, a means of transporting men and materials to the upper levels of the 43m steel Reformer Tower was required. An Alimak Scando rack and pinion hoist proved the perfect solution, meeting size, weight, capacity and height requirements on site.
Alimak engineers designed and manufactured unique brackets with extra long ties to fasten the mast sections to the tower’s irregular steel structure, in accordance with petro-chemical plant safety requirements. In addition, extended landing platforms were fitted at the 33m and 37m landings, providing a safe walkway from hoist car to tower.
Meeting plant safety & operating requirements
Installation and dismantle of the temporary rack and pinion hoist was carried out in compliance with strict site working regulations, with Alimak technicians monitoring the use of all power tools and completing work within pre-arranged time frames.
Location: Petroleum Refinery, Australia
Product model: ALIMAK SCANDO 12/20
Application: Refinery shutdown, temporary hoist
No. of landings: 2
Capacity: 1200 kg
Car size: 2.0 m x 1.5 m
Speed: 40 m/min
Lifting height: 37 m
In celebration of 25 years of service, Alimak looks back on one of the largest and most unique projects the company has undertaken worldwide, and the contribution Alimak has made to one of the Australia’s most recognisable structures.
In 1986, Alimak designed, manufactured and installed two industrial elevators on one of Australia’s most iconic and historical buildings.
In 1978 Prime Minister Malcolm Fraser unveiled plans to build a new Parliament House in celebration of Australia’s 200th birthday. Designed by Mitchell/Giurgola & Thorp Architects, the new Parliament House would feature six times the floor space of the original structure, accommodating more than 5,000 people. When construction began in 1981 it was the most expensive building in the world, valued at an estimated AUS $1.1 billion.
Opened by Queen Elizabeth II on 9 May 1988, the unveiling of the new Parliament House coincided with a celebration of 200 years of European settlement and the anniversary of the opening of the First Federal Parliament in Melbourne on May 9, 1901.
The shape of the building aligns with the land axis designed by architect Walter Burley Griffin in his original master plan for Canberra. The walls curve out to form the start of the Parliamentary Triangle, while an 81 metre stainless steel flagpole, anchored to four bow-formed steel legs, sits atop the central building.
As a visual focus point and stunning centrepiece, the flagmast was comprised of 220 tonnes of Newcastle stainless steel, raising a 25kg Australian flag, half the size of a tennis court.
The flagpole itself was designed to be completely illuminated at night by an intricate series of timed lighting fixtures contained within the flagpole’s ‘cluster’; the point at which the four stainless steel legs meet, giving support to the 81m flagpole. Also contained within this ‘cluster’ is the platform from which the flag may be fastened and detached from the flag pole halyard. During the design phase of the new Parliament House the question arose, if something were to go wrong with the lighting or mechanical winching systems, how would anyone gain access to the flagpole for maintenance or repairs? Alimak consultants provided the perfect solution.
Preserving the ‘clean lines’ of the structure
In 1985 Alimak was awarded the contract for the design, manufacture and installation of two specially designed rack and pinion industrial elevators. Alimak worked closely with project architects and managers on the design, engineering and aesthetics of incorporating the two rack and pinion elevators into the flagpole structure. In order to preserve the visual impact of the new Parliament House, it was essential that the flagmast have clean lines and not be visually disturbed by the intrusion of the elevators. To achieve this, Alimak engineers designed a unique stainless-steel rack which could be bolted directly onto the stainless steel leg, without the use of a mast. In this way, the rack was hidden from public view, camouflaged against the flag mast leg.
Design and Manufacture
This complex new rack system required the use of a soft bronze pinion to run on the hardened stainless steel rack, in place of the standard improved-capacity steel pinion. The benefits of using a bronze pinion were threefold: The pinion would contain wear of the elevator to a single component enclosed within the gearbox, instead of wear to the entire 81m of rack; it would allow the elevator to operate without the need of lubricants, avoiding any potential ‘staining’ of the stainless steel flagpole leg; and it minimised movement of the elevator car on the rack and reduced operational noise.
To preserve the aesthetic feel of the building, each elevator was painted to match the satin finish of the stainless steel flagpole, and was designed to be parked behind a recess of the building. The result of this was that both elevators would remain hidden from the public view when not in use, and cosmetically, the façade of the building would remain unchanged. The two units were designed and manufactured in Sweden, in compliance with both Swedish National Standards and Australian Standards, and arrived on site at Parliament House in October 1986.
Dual Elevator Concept
Alimak’s unique solution to the challenge at Parliament House was a dual elevator concept: one elevator to travel the 61m up the southeast flagmast leg, at a 40° inclination, to the first landing platform, and a second elevator to continue the additional 24m to the apex of the tapered flagpole.
The lower elevator, with a capacity of 300kg and equipped to carry 3 persons at a speed of 9m/min, travels the 50m of the stainless steel leg to the first cluster platform, and from there can travel an additional 10m to the second cluster platform. The first cluster platform is used predominantly as structural support for the flagpole; the second platform facilitates the changing of the flag and houses the flagpole lighting system.
Access to the two cluster landing platforms is achieved via an electric/hydraulic drawbridge contained within the elevator. Upon reaching the cluster landing, this transfer bridge extends from the elevator and is lowered onto the platform, forming a walkway. This allows passage from the elevator car to each of the two cluster platforms, allowing personnel to exit the elevator to complete necessary maintenance on the landings.
The upper elevator, with a capacity of 100kg, is equipped to carry a single person the additional 24m to the very top of the flagpole, allowing personnel to reach the external ropes, pulley system and the hoisted flag, should the winch system fail or the sheaves require replacing.
Alimak’s two galvanised steel elevators arrived on site at Parliament House in October of 1986, and were fully installed and operational by May of 1987. The installation occurred in stages, the first of which involved much of the rack being systematically bolted to the stainless steel support leg, as the flagpole structure was being erected. The second stage involved the remaining 75kg lengths of rack being manhandled into the lower elevator, driven up to the correct position, winched through the roof trap door, and bolted into place. The curved 150kg section of rail, which was to negotiate the 40° incline of the flagpole leg, was manoeuvred into place with use of the on-site tower crane. Given the triangular shape of the support leg, and variations in the metal, stainless steel shims were fixed to the structure to ensure the rack would remain perfectly level when bolted into position.
The two Alimak rack and pinion elevators have remained in operation at Parliament House for 25 years, servicing the central flagpole from which the Australian flag flies.
Alimak’s unique rack and pinion system enabled the elevator to negotiate the sharp curve of the leg, shifting from a near horizontal 40° angle to vertical upright along the same rack. Alimak safety devices, centrifugal brakes and automatic lowering systems allow both elevators to be lowered by gravity at a controlled speed in the case of an unexpected power supply problem.
Changing the flag
The flag, measuring 12.8 m x 6.4 m, is changed every four to six weeks due to weather damage and requires three personnel to carry out the change-over. A single person must operate the hand winching system located on the NorthEast wall of the structure in order to lower the flag to the second landing platform. While this occurs, two personnel must use the lower Alimak elevator to travel the 61m to the second landing platform in order to physically detach and replace the flag. The flag may then be raised once more, using the winching system operated from the ground.
Additional support from Alimak
Since the installation of the two rack and pinion elevators in 1987, Alimak has completed services on both elevators every four years to ensure the exchange of safety devices and perform drop tests. Routine service and maintenance of the flagpole, elevators and winching system is conducted by Parliament House’s own DPS Mechanical Services staff. In 1990 a minor refurbishment was completed on the lower elevator in order to replace a gear box and centrifugal brake assembly. Given the location of the elevator, and the difficulties in gaining access to the flagpole structure, an Australian Army helicopter was enlisted to hoist the 50kg gear box from the elevator car, and transport it to a nearby maintenance vehicle. The gearbox was then transported to a workshop for refurbishment, and replaced once more with the help of a helicopter.
The two Alimak rack and pinion elevators have remained in operation at Parliament House for 25 years, servicing the central flagpole from which the Australian flag flies. The unique nature of the project, coupled with the engineering and design challenges involved, has made this one of the largest projects completed by Alimak worldwide. 25 years on, Alimak celebrates one of its proudest achievements and the contribution made to one of Australia’s most iconic structures.
Location: Parliament House, Canberra, Australia
Installation year: 1986
Application: Flagmast, elevator access
Elevator type: Alimak 300 kg, Alimak 100 kg
Lifting height: 81 m
Capacity: 300 kg, 100 kg
Alimak configures the Alimak SE 1200 industrial elevator with an explosion-proof rating to meet the hazardous zone requirements of the North Rankin A gas platform. With external call stations for non-man riding, the luggage elevator may be called, loaded and directed to the required level.
Redevelopment and expansion of the North Rankin A platform by the Woodside-operated North West Shelf Project includes the installation of a new North Rankin B Platform, connected by two 100 m bridges to the existing North Rankin A Platform. Located 135km north-west of Karratha, the NRA platform is one of the largest capacity gas production platforms in the world, producing more than 51,000 tonnes of gas and gas condensate daily.
Rack and pinion luggage elevator
In March 2012, Woodside installed an Alimak SE 1200 industrial lift, with explosion-proof rating, on the North Rankin A platform . Available for use 24-hours a day, the luggage lift services the accommodation facilities on board the platform, transporting workers’ luggage from the top of the accommodation module to the South Bridge Pedestrian Landing.
Given the hazardous zone requirements of the gas production platform, Alimak had three project challenges: first, that the lift be configured to an Ex (Explosion Proof) rating; second, the lift be fitted for non-man riding with external controls; and third, the lift undergo both an onshore and offshore installation in order to reduce the time required to complete the installation, testing and commissioning on the platform itself.
An explosion proof elevator
Given the lift’s location on an offshore gas platform, hazardous zone requirements dictated the lift be configured with an Ex-rating. Alimak worked closely with the client to ensure the lift met both the client specifications and zone requirements. To achieve an Ex rating, the lift was designed and manufactured in compliance with the designated hazardous area requirements, classified under Zone 2, Gas Group IIA and Temperature Class T3. In accordance with the Ex-rating of the lift, Alimak provided complete Ex documentation and commissioning work packs for both the onshore and offshore installation phases.
As the lift was required to provide a safe, all-weather means of transporting luggage on board the platform, it was necessary that the lift be fitted with external call stations for non-man riding. In accordance with client specifications, Alimak modified the electrical control circuit to allow for use of the ‘call and send’ feature. Given the luggage lift was for transporting of materials only, these external controls allowed personnel to operate the lift without the need to travel inside it. In this way, operators could ‘call’ the lift using external call switches located on both the Passenger Living Quarters Roof and the South Bridge Pedestrian Landing, and then ‘send’ the lift to the required level .
Alimak completed both onshore and offshore installation, testing and commissioning of the lift in order to keep installation and training time on board the platform to a minimum.
In order to keep installation and training time on board the offshore platform to a minimum, Alimak completed both onshore and offshore commissioning, and maintenance and operation training for the lift. Onshore installation took place in the AOG shipyard in Kwinana, Western Australia. The lift shaft was constructed and erected at the onshore facility, allowing the lift to undergo full installation, testing and commissioning within the constructed lift shaft. Following onshore installation, the lift car was braced within the lift shaft, turned on its side and transported to the offshore platform for the final phase of commissioning.
Once erected on the offshore platform, the lift and lift shaft underwent the final stage of testing and commissioning, with personnel training conducted by Alimak certified technicians.
The Alimak SE-Ex 1200 lift has been in operation on the North Rankin A platform since March 2012. Designed for intermittent service, the luggage goods lift has an expected life of 30 years minimum with regular maintenance.
Location: North Rankin A Platform, Indian Ocean, Australia
Product Model: Alimak SE-Ex 1200
Application: Gas production platform, luggage elevator
No. of landings: 2
Capacity: 1200 kg
Car size: 1.6 m x 1.7 m
Speed 0.6 m/s
Lifting height: 11 m
An Alimak SE rack and pinion industrial elevator is installed within an access tower at Williamstown Shipyard’s Nelson Pier. Used as the primary means of gaining access to the hulls of docked ships, the Alimak elevator improves safety at the shipyard by providing emergency and stretcher access.
Providing access to ship hulls
Alimak was awarded the contract to design, manufacture and install an Alimak rack and pinion men and materials elevator at Williamstown Shipyard’s Nelson Pier. Located in the north of Melbourne’s Port Phillip Bay, Nelson Pier has undergone a multi-million dollar upgrade to accommodate increased traffic at the port. Infrastructure improvements included the construction of a new 40m mooring dolphin, access towers and brows to allow personnel and equipment to reach ship hull-decks from the pier level. An Alimak industrial rack and pinion elevator was pre-designed into the new infrastructure to provide vertical transport to the hulls of docked ships, via the pier’s access tower.
Flexibility and extended car size
Commissioned in July 2012, the Alimak SE elevator provides vertical access to ships’ hulls from the pier ground level, allowing for the easy movement of men, materials and equipment, as well as providing emergency stretcher access. Site conditions made it necessary for the elevator to be fitted to the inclined ramp of the pier; the flexible nature of the Alimak SE industrial elevator range made this easily possible.
As the primary means of access to the hulls of ships docked at Nelson Pier, the Alimak industrial elevator is used to transport personnel, materials, tools and equipment, freeing up use of the pier cranes. Selected for its extended car size and 1600kg capacity, the Alimak SE elevator is capable of carrying palletized loads and emergency stretchers.
Emergency access and evacuation
The incorporation of the Alimak elevator into the pier’s access tower has improved efficiency and safety on the shipyard site by providing a means of emergency access and evacuation. In the event of an injured person on a ship’s hull, the Alimak industrial elevator allows an emergency response team to reach and safely transport injured workers using a stretcher.
Ideally suited for operation in even the most extreme environments, the durable nature of the Alimak SE range of elevators has made it the perfect access solution for the exposed pier. Composed of hot-dipped galvanized steel, the Alimak industrial elevator ensures maximum operator comfort and usability, without compromising on efficiency.
Alimak service technicians identify and replace 70 m of corroded mast and base frame to extend the life of a 26-year-old maintenance lift. Given the close proximity to power lines and the confined space, a clever solution was required to complete the mast refurbishment.
Grain processing facilities
Founded in 1916, Graincorp operate seven bulk grain export elevators in Eastern Australia, boasting a combined grain storage capacity of 20 million tonnes. Processing wheat, barley, canola, chickpeas and sorghum, delivered by road and Graincorp’s extensive rail network, these facilities handle more than 5 million tonnes of grain annually.
Installed in 1986, Graincorp’s Gladstone facility makes use of an Alimak rack and pinion lift to access the seven landings of their 70m grain stack. A critical piece of equipment on site, the Alimak lift allows maintenance staff to access higher levels of the stack for necessary servicing and maintenance. The lift also enables swift and safe access for emergency response if required.
Servicing identifies corrosion to the mast
Following an on-site service inspection, Alimak identified irreparable corrosive damage that had occurred to the base mast, base frame and a mast section located 25m up the grain stack. Both sections were damaged beyond repair and required the entire 70m mast and base frame to be dismantled and replaced.
Given the close proximity of power lines to the grain stack, Alimak was unable to angle a crane close enough to dismantle the lift mast. Without the use of a crane, mast sections could not be maneuvered over the power lines. A temporary disconnection of the lines would result in a shut down of Graincorp’s entire Queensland rail system.
A clever solution
In order to replace the damaged mast, Alimak engineered and installed a unique winch that would allow the mast to be dismantled and reassembled manually. Fixed to the Alimak lift car, the Alimak winch was able to hook each mast section individually and angle the section onto the lift car roof area. Operators were then able to use the lift itself to deliver each section to the ground.
In this way, each of the Gladstone grain stack’s 49 mast sections were manually dismantled, with the same process used in reverse to assemble the replacement mast. Alimak worked closely with Graincorp throughout the duration of the project, providing engineering technical, electrical and rigging support.
The Alimak rack and pinion lift’s replacement mast has been in operation at the Gladstone facility since May 2012, providing Graincorp operators with access to the 7 levels of the grain stack. Alimak’s manual winch approach may be used in future projects where site restrictions prevent crane access.
Location: Graincorp Grain Handling Facility, QLD, Australia
Installation year: 1986
Application: Grain handling facility, lift access
Lift type: Alimak Scando 10/19
No. of landings: 7
Capacity: 1000 kg
Car size: 1.9 m x 1.2 m
Speed: 0.65 m/sec
Lifting height: 70 m
An Alimak rack and pinion industrial elevator is pre-designed into Dyno Nobel’s Moranbah ammonium nitrate plant, providing maintenance access to the 70m prill tower. Alimak utilised a crane to lower the elevator into the existing tower shaft during installation.
A growing demand for mining explosives
The Dyno Nobel ammonium nitrate plant, located in Queensland’s coal-rich Bowen Basin, is part of Incitec Pivot’s $935 million Moranbah nitrate manufacturing complex. The fully-integrated back-to-gas complex includes ammonia, nitric acid and ammonium nitrate plants, producing the raw materials needed to service Australia’s growing demand for mining explosives. Construction of the complex began in 2006, and after several scheduling delays, was completed in early 2012.
Providing access to the penthouse
Included in the construction of the ammonium nitrate plant was the erection of a 70m prill tower to be used in the ammonium nitrate solidification process. Dyno Nobel specified the inclusion of an Alimak rack and pinion industrial elevator into the design of the prill tower, in order to provide operations and maintenance staff with access to the tower’s top ‘penthouse’.
Alimak worked closely with Dyno Nobel, providing engineering support for the design of the tie-in points and landings, pit design and electrical supply requirements.
Installation within a pre-existing elevator shaft
Installation of the industrial elevator proved challenging, with the elevator to be installed within a pre-existing shaft area of the prill tower. To accomplish this, elevator components were lowered from the 70m tower using cranes, while the Alimak installation team used a crane-hung ‘dog-box’ to access main tie-in points.
With a lifting height of 65m, providing access to the three landings of the prill tower, the Alimak industrial elevator is used for general maintenance on a daily basis and accommodates extra personnel and equipment during heavy-usage shutdown periods.
Location: Dyno Nobel Ammonium Nitrate Plant, Moranbah, Australia
Application: Prill tower, access elevator
Elevator type: Rack and pinion
Elevator model: ALIMAK SE 700
Capacity: 700 kg
Elevator car size: 1.04 m x 1.17 m x 2.17 m (W x L x H)
Speed: 1.0 m/s
Lifting height: 65 m
Crushing Services International specifies three Alimak SE 1200 kg industrial lifts for inclusion on the Christmas Creek Mine expansion. Installed in the mine’s iron ore processing facilities, these are the first permanent Alimak lifts in Australia installed on an iron ore crushing plant.
Iron ore mining expansion
Fortescue Metal’s Christmas Creek mining operations has undergone a two phase expansion program to increase the capacity of the mine’s iron ore operations. Located in the east Pilbara region of Western Australia, the Christmas Creek mine expansion included the construction of two ore processing facilities and a crushing hub; the first in Australia to be fitted with Alimak industrial men and materials lifts. Completed in December 2012, the expansion has increased production to more than 50 million tonnes of ore per annum.
Minimizing plant downtime
As the prime contractor for the expansion’s construction works, Crushing Services International specified the inclusion of the lifts in the ore processing facilities in order to maximize plant reliability. Minimizing production downtime at the processing facilities was a critical factor, as the iron ore requires crushing, screening and processing prior to sale and transport. Used for the transportation of materials, equipment and the operations and maintenance personnel on site daily, the three Alimak SE 1200kg industrial lifts improve efficiency of operations at a key stage of the mine’s processing circuit.
Phase one: taking advantage of limited space
Phase one of the expansion involved the construction of a 20mtpa ore processing plant, used to crush, screen, scrub and de-sand the wet table ore. The first Alimak industrial lift was installed in the de-sands building of the processing plant in March 2011, and required careful engineering to fit the lift system inside an existing portion of the building’s structure. In order to take full advantage of the limited space available, an Alimak FE mast was selected for its narrower depth and smaller dimensions, in place of the standard Alimak 650 mast.
Phase two: a second and third elevator are installed
Phase two of the expansion included the construction of a second ore processing plant and a remote crushing hub. The second Alimak 1200kg industrial lift was installed in the facility’s tertiary crusher in May 2012, while February 2013 saw the final Alimak lift installed in Plant 2’s de-sands building.
Improving safety and efficiency on-site
The Alimak SE 1200kg personnel and materials lift was selected for all three buildings due to its flexible size. With a car size of 1.3 m x 2.1 m, the Alimak SE 1200 is suited to carry palletized loads and improves safety and emergency procedures on site by accommodating the dimensions of an emergency stretcher.
Location: WA, Australia
Product Model: Alimak SE 1200
Lift Type: Rack and Pinion
Application: Iron ore processing facility, lift access
No. of Lifts: 3
Capacity: 1200 kg
Car Size: 1.3 m x 2.1 m
Speed: 0.6m /sec