Roof lifting / San Mamés Stadium, Spain
Primarily assembled on the ground, the cable structure was then lifted to its final position at a 50 m height, with 160 strand jacks simultaneously monitored by video.
Lifting and handling heavy structures are complex operations. We deliver tailored solutions adapted to each project configuration, from early design to final operation.
Whether occurring during a design-build project or as a primary step to perform repair or maintenance activities, lifting or handling heavy structures remains challenging. It demands control over the stresses induced in the structure throughout the whole process. Conducting such operations requires engineering expertise, reliable equipment, careful operating, and precise placement. Relying on skilled and experienced teams and thorough risk management to ensure worker safety, structure preservation, and worksite surroundings protection is essential, especially when these operations are carried out in dense urban areas.
From cable-stayed bridge rotation to stadium roof lifting, from underpass bridge sliding to hauling-up of water tower tanks, through to jacking-up operations, we will offer you the most appropriate solutions, especially when other conventional installation methods are impractical, risky or too costly.
Heavy handling includes:
- heavy lifting, which consists in moving a structure or a load vertically,
- sliding, which involves the horizontal shift of a structure or a load,
- rotation sometimes, when the operation also entails a change in orientation of the structure.
Complex projects may often necessitate to combine several operations, especially when adjusting the structure in its final position. This is where our expertise, specialist teams and capability to drive and manage the project in all aspects will make the difference.
Benefits
Why choose Freyssinet for your project
01. Over 40 years’ experience
In the most complex, small and large-scale operations
02. Time-saving operation
Reducing installation activities on the critical path
03. Reduced site interferences
Few interferences with other site activities until the structure is moved and installed in its final position
04. Extensive service offering
From concept design to implementation
05. Reduce traffic disruption
Minimize disturbance as structures are built next to the traffic line and moved to the final position during a very short track closure
06. Documented risk management
With HAZID/HAZOP type assessment of each handling or lifting operation
07. Exclusive technologies
State-of-the-art Hebetec hydraulic equipment and Megasteel® temporary structures
08. High safety standards
Services tailored to your needs
From design to execution
From concept design to engineering studies
From the early stages of the proposal, Freyssinet and Hebetec Engineering will include a primary concept design for the structure’s heavy lifting and / or handling. In a second stage, our teams develop the preliminary and detailed design of the operation, based on our clients’ input.
We will ultimately define the optimal solution that meets your specifications in terms of safety, structural integrity, efficiency, phasing of works, budget, and lead times.
Supply and installation of hydraulic equipment
Combining our expertise with the know-how of our sister company Hebetec Engineering, we propose a range of lifting and handling equipment whose precision and real-time control capabilities enable a strict management of the entire operation. Our specialist teams will provide the most appropriate equipment to meet your needs.
Credit: Courtesy picture by ©Sam Burbank CEC
Supply and installation of temporary structures
Most lifting or jacking operations require the additional use of temporary structures. Together with Hebetec Engineering, our expert teams offer a guaranteed turnkey service including the design, supply, and installation of Megasteel® and Mega-tube structures, and performance of structural checking and loading controls.
Operations execution
Combining Freyssinet & Hebetec Engineering experience, our specialist teams can conduct the lifting or handling operations safely while ensuring regular checking on permanent structures at all works stages.
Discover our case studies
Build
France
Paris La Défense Arena roof lifting operation
1,700-tons roof lifting operation for one of the largest multi-use domed stadiums in Europe
Build
France
CNIT underground station jacking
The construction of a station located underneath a Paris shopping centre required the taking up of a load of a frame assembly of some 100,000 tonnes, thanks to an innovative jacking system.
New build
Hong Kong
Yuen Long Station LTR footbridge erection
The project involves the construction of two 50m-long bridges above the light rail tracks, in non-traffic hours only, making the use of conventional erection method impossible.
Build
UK
Immingham bridge: underpass autofonçage
Meticulous contingency planning and an innovative underpass bridge sliding technique were the keys that enabled a crucial railway line to reopen on time despite the British weather.
Build
Volgograd arena cable-stayed roof
The Freyssinet teams designed, assembled and lifted the roof of the Volgograd Arena, a 1,600-t cable-stayed structure erected at 48 m. Cable-stayed structure using a Big Lift technique.
The Freyssinet teams designed, assembled and lifted the roof of the Volgograd Arena, a 1,600-t cable-stayed structure erected at 48 m. Cable-stayed structure using a Big Lift technique.
Build
Canada
Vendôme station tunnel installed by Autoripage
Creation of a pedestrian tunnel under the railway tracks of the Vendôme metro station in Montreal by Autoripage.
Build
France
Allonne bridge construction by rotation
Installation of a cable-stayed bridge by rotation over a heavily trafficked motorway whose configuration does not allow for a traditional incremental launching construction method.
Heavy lifting can be performed at different heights, depending on the structure or load to be lifted (dimensions, shape, weight…), worksite configuration, and purpose of the operation. To handle the structure or load involved, our teams operate the strand lifting or precision jacking methods.
Strand lifting
Heavy lifting using the strand jacking technology can be performed to quickly raise or lower almost any load, regardless of the height. This method is an appropriate solution when lifts have large dimensions, when loads require several lifting points, must be moved horizontally at heights, or require precise handling or placement in their final position.
Credit: ©Francis Vigouroux
Credit: ©Francis Vigouroux
- Cost-effective method
- Fast process completion
- Improved safety conditions
Precision jacking
This technique ensures safe and accurate lifting/lowering of rigid structures necessarily requiring multiple lifting points, due to uninterrupted control of the load movements in operations such as structure raising or decentering and bearing replacement. Computer-aided jacking operations can be performed in confined areas and support up to several thousand tons by several meters. Our computer-aided LAO® jacking system designed in-house has 48 separate hydraulic ways which already allowed us to lift structures up to 100,000 tons with a 0.3 mm accuracy.
- Real-time control
- Constant analysis of
lifting parameters - Monitoring of stroke variations
between lifting jacks
Strand lifting
Heavy lifting using the strand jacking technology can be performed to quickly raise or lower almost any load, regardless of the height. This method is an appropriate solution when lifts have large dimensions, when loads require several lifting points, must be moved horizontally at heights, or require precise handling or placement in their final position.
Credit: ©Francis Vigouroux
Credit: ©Francis Vigouroux
- Cost-effective method
- Fast process completion
- Improved safety conditions
Precision jacking
This technique ensures safe and accurate lifting/lowering of rigid structures necessarily requiring multiple lifting points, due to uninterrupted control of the load movements in operations such as structure raising or decentering and bearing replacement. Computer-aided jacking operations can be performed in confined areas and support up to several thousand tons by several meters. Our computer-aided LAO® jacking system designed in-house has 48 separate hydraulic ways which already allowed us to lift structures up to 100,000 tons with a 0.3 mm accuracy.
- Real-time control
- Constant analysis of
lifting parameters - Monitoring of stroke variations
between lifting jacks
Gallery
Related projects
Bridge lowering / Oakland Bay Bridge, USA
As part of demolition works in San Francisco Bay, lowering of five 1,600-ton bridge trusses onto barges from heights up to 50 metres, using strand jacks while ensuring stable load balance during the execution operated at a speed of up to 14 m/h.
Temporary structures / Atlantic Bridge, Panama
As part of the construction of the cable-stayed bridge with the longest concrete deck span in the world (530m), delivery of a Megasteel self-erecting system to temporarily support the 120-ton formwork and 1,600-ton bridge concrete elements.
Eolift / Santa Monica wind farm, Brazil
Development of a new concrete tower design based on the use of precast segments (match-casting method), and of an innovative erection method. Added value of these innovations: construction time frame and cost reductions, lower carbon footprint than conventional steel towers.
Heavy lifting / Forth Crossing Bridge, Scotland
Supply of strand jacks, hydraulic systems and control units to operate the six traveller steel frames used to lift bridge decks from barges into position during the construction of the world longest three-tower cable-stayed bridge. Installation supervision and execution of the system operation was conducted by Hebetec as well.
Nuclear power plant in Mühleberg, Switzerland - A 230t. lifting structure was built to bring out two generators of 150 tons each
Ashalim Solar Power Station, Israel - heavy lifting of the 2,300 t boiler to its final position, at a height of 200 m
Railway bridge at Lancy, Switzerland - The lowering system developed by Hebetec Engineering Ltd.
and applied by Freyssinet expert teams ensured horizontal stability owing to a telescopic system fixed to the bridge piers.
and applied by Freyssinet expert teams ensured horizontal stability owing to a telescopic system fixed to the bridge piers.
Power plant in Leuna, Germany - Strand lifting of the waste-heat boiler’s modules for installation in the new-build heating power plant.
in a short time frame of 5 weeks to hoist the 300-tonne overall load to a height of 20 metres.
in a short time frame of 5 weeks to hoist the 300-tonne overall load to a height of 20 metres.
Some more case studies ...
Build
France
CNIT underground station jacking
The construction of a station located underneath a Paris shopping centre required the taking up of a load of a frame assembly of some 100,000 tonnes, thanks to an innovative jacking system.
Build
France
CNIT underground station jacking
The construction of a station located underneath a Paris shopping centre required the taking up of a load of a frame assembly of some 100,000 tonnes, thanks to an innovative jacking system.
Hebetec, the Freyssinet lifting and heavy handling specialist
Visit the websiteHebetec, the Freyssinet lifting and heavy handling specialist
Visit the websiteSliding and rotation operations are used to install structures that must overpass or underpass obstacles like railroad, highway, or valley crossings.
These operations can be performed at ground level on a short distance, and at heights, when heavy structures are shifted to their final position or when heavy loads are removed from their current position. These methods apply to new build projects, structure dismantling or when replacing part of an existing structure.
Launching
Launching is a longitudinal sliding method that allows to cross gaps. It is the preferred construction method for bridges crossing valleys or rivers. The bridge deck is prefabricated behind one of the abutments. Installation consists in sliding deck sections over sliding bearings onto the bridge piers, while a launching nose prevents bending moments, as part of the installation is done above the void. Launch is operated with high-capacity hydraulic jacks.
- Cost-effective solution
- Minimal traffic disruption of underpass lanes
- No impact of bridge height
Autoripage® structure sliding technique
This patented method developed by Freyssinet enables the installation of a structure entirely prefabricated on a nearby base -usually next to the road or railway track - and sliding it to its final position onto bentonite grout, after completely clearing the ground. After sliding completion, backfilling is carried out to re-open the route to traffic. The method is particularly appropriate for railroad crossing.
- Fast execution
- Short track closure
- New structure built near final position
Autofonçage® structure sliding technique
Also developed by Freyssinet, Autofonçage® is a patented structure sliding method which enables the creation of a short underpass structure under traffic lanes in operation. It consists in prefabricating sections of the structure (concrete frames), then sliding them after partly clearing the ground and driving the structure forward into the infill as the excavation work progresses. No backfilling is required, as the volume of earth excavated equals that of the structure.
- Fast execution
- Reduced traffic disruption
- Structure sections built near final position
Air Pad Sliding
Air Pad Sliding (APS) is an alternative to Autoripage® using APS bearings, a patented device: after clearing the ground, heavy structures are horizontally moved to their final position along skidways onto APS modules. Skidways are equipped with side guides and adapted to the bearing capacity of the soil. Once the sliding operation is completed, backfilling takes place to re-open the route to traffic.
- Friction coefficient <1 %
- Skidding speed up to 150m/h
- Multidirectional lifting and sliding
Lateral sliding
When a bridge deck needs to be replaced, a practical solution consists in building the new one next to the old one. Therefore, the new deck is built on a temporary support. Once completed and during a short possession, the old deck is de-slided and the new one slided into final position. This method allows replacement of long decks at heights, when cranage is impossible.
- Friction coefficient < 5%
- Sliding speed up to 15m/h
- Long and heavy slide
Rotation
When it is impossible or costly to build overpass bridges above the obstacle to overcome (e.g. motorway in operation), rotation operations are interesting solutions to install bridges in their final position. In this case, the structure is built perpendicular to its final position, along the track. Rotation is operated from a central pivot or from an end pivot (located at one of the bridge deck’s ends).
- Friction coefficient < 5%
- Minimum traffic disruption
Launching
Launching is a longitudinal sliding method that allows to cross gaps. It is the preferred construction method for bridges crossing valleys or rivers. The bridge deck is prefabricated behind one of the abutments. Installation consists in sliding deck sections over sliding bearings onto the bridge piers, while a launching nose prevents bending moments, as part of the installation is done above the void. Launch is operated with high-capacity hydraulic jacks.
- Cost-effective solution
- Minimal traffic disruption of underpass lanes
- No impact of bridge height
Autoripage® structure sliding technique
This patented method developed by Freyssinet enables the installation of a structure entirely prefabricated on a nearby base -usually next to the road or railway track - and sliding it to its final position onto bentonite grout, after completely clearing the ground. After sliding completion, backfilling is carried out to re-open the route to traffic. The method is particularly appropriate for railroad crossing.
- Fast execution
- Short track closure
- New structure built near final position
Autofonçage® structure sliding technique
Also developed by Freyssinet, Autofonçage® is a patented structure sliding method which enables the creation of a short underpass structure under traffic lanes in operation. It consists in prefabricating sections of the structure (concrete frames), then sliding them after partly clearing the ground and driving the structure forward into the infill as the excavation work progresses. No backfilling is required, as the volume of earth excavated equals that of the structure.
- Fast execution
- Reduced traffic disruption
- Structure sections built near final position
Air Pad Sliding
Air Pad Sliding (APS) is an alternative to Autoripage® using APS bearings, a patented device: after clearing the ground, heavy structures are horizontally moved to their final position along skidways onto APS modules. Skidways are equipped with side guides and adapted to the bearing capacity of the soil. Once the sliding operation is completed, backfilling takes place to re-open the route to traffic.
- Friction coefficient <1 %
- Skidding speed up to 150m/h
- Multidirectional lifting and sliding
Lateral sliding
When a bridge deck needs to be replaced, a practical solution consists in building the new one next to the old one. Therefore, the new deck is built on a temporary support. Once completed and during a short possession, the old deck is de-slided and the new one slided into final position. This method allows replacement of long decks at heights, when cranage is impossible.
- Friction coefficient < 5%
- Sliding speed up to 15m/h
- Long and heavy slide
Rotation
When it is impossible or costly to build overpass bridges above the obstacle to overcome (e.g. motorway in operation), rotation operations are interesting solutions to install bridges in their final position. In this case, the structure is built perpendicular to its final position, along the track. Rotation is operated from a central pivot or from an end pivot (located at one of the bridge deck’s ends).
- Friction coefficient < 5%
- Minimum traffic disruption
Gallery
Related projects
Luftbild, Neubau der Lennetalbrücke A45, Berchum, Sauerlandlinie, Autobahnbrücke, Hagen, Ruhrgebiet, Nordrhein-Westfalen, Deutschland ACHTUNGxMINDESTHONORARx60xEURO *** Aerial photograph, new construction of the Lennetal bridge A45, Berchum, Sauerlandlinie, motorway bridge, Hagen, Ruhr area, North Rhine-Westphalia, Germany ATTENTIONxMINDESTHONORARYx60xEURO
Lateral sliding / Lennetal Highway Bridge, Germany
It took less than 6 hours to move the 30,000 ton, 1,000-metre-long Bridge by 19.15 meters sideways in its final position.
Load out / Oil Rig Baronia at Ulsan, Korea
17’000 ton weighing oil rig was shifted to load on bord of a barge and eventually put into operation in the Gulf of Thailand
Combined APS sliding & heavy lifting operations / Ashalim Solar Power Station, Israel
APS sliding of a 2,300t. boiler on 64 m from the assembly area to the power station tower
Bridge launching / Bowstring bridge, Casablanca, Morocco
The 330-ton steel structure of the Bowstring Bridge was launched over the A3 city highway crossing. The operation took place overnight, resulting in a short traffic closure and minimal disruption as the arch bridge was pre-assembled next to the roadway.
More case studies
Build
France
Allonne bridge construction by rotation
Installation of a cable-stayed bridge by rotation over a heavily trafficked motorway whose configuration does not allow for a traditional incremental launching construction method.
New build
Hong Kong
Yuen Long Station LTR footbridge erection
The project involves the construction of two 50m-long bridges above the light rail tracks, in non-traffic hours only, making the use of conventional erection method impossible.
Build
Canada
Vendôme station tunnel installed by Autoripage
Creation of a pedestrian tunnel under the railway tracks of the Vendôme metro station in Montreal by Autoripage.
Build
UK
Immingham bridge: underpass autofonçage
Meticulous contingency planning and an innovative underpass bridge sliding technique were the keys that enabled a crucial railway line to reopen on time despite the British weather.
Repair
France
Marly-le-Roi viaduct steel deck replacement
Given the very dense urban area and limited ground space available, replacement of the bridge steel deck had to be performed at heights, with consecutive lateral sliding operations.
Hebetec, the Freyssinet lifting and heavy handling specialist
Visit the websiteHebetec, the Freyssinet lifting and heavy handling specialist
Visit the websiteContact us
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