Dorman Long Technology

Integrated Heavy Lifting Contractor and Construction Consultant

Bridge construction Buildings/structures Refinery construction

Offshore construction Heavy Lifting Jacking systems

Roof erection Airport construction Erection gantries

V1.8a wwww.dormanlongtechnology.com
Page 2

Contents

Introduction to DLT Page 3

Heavy lifting contracting services Page 4

Consulting services Page 5
Jacking systems Page 6

Reference projects:
Bridges Page 7
Buildings & structures Page 10
Heavy lifting Page 12
Erection gantries Page 14
Refinery construction Page 16
Offshore construction Page 17

Project data sheets:

Boyne cable stayed bridge, Ireland Page 18
Carquinez suspension bridge, California Page 19
Orinoco river second crossing, Venezuela Page 20
Paddington station LTVA bridge replacement, UK Page 22
Tuti suspension bridge, Sudan Page 23
Blast Furnace re-lining project, Taiwan Page 24
Runyang suspension bridge deck erection gantries, China Page 25
Sutong Cable stayed bridge, cofferdam lowering, China Page 26
Sheikh Khalifa bin Salaman Causeway bridge, Bahrain Page 27
Tamar suspension bridge widening, UK Page 28
Heathrow terminal 5, main building and control tower Page 29
Wembley stadium arch and roof erection Page 30
HAECO hanger roof lift, Hong Kong Page 31
2500 tonne capacity self-erect jacking tower system, China Page 32
Gatwick airport passenger bridge erection, UK Page 33
FHIC modular jacking tower system for heavy vessel erection Page 34
Tsing Ma suspension bridge, Hong Kong Page 35

Contact details Page 36

For up to date information on current projects please refer to our web site.
 Page 3

Introduction
Dorman Long Technology offer a wide range of contracting, consulting and equipment supply
services, which are tailored to add value to each project that we are employed on. We combine
specialist product and contracting services with world-class engineering to produce a strong
competitive advantage, both for ourselves and for our clients.

Comprehensive service
We offer an exceptional combination of consulting and contracting services to the construction
industry. Our unique combination of experienced permanent and temporary works design engineers
coupled with our highly valued team of site managers and engineers enables us to make a valuable
contribution to your project, from initial scheme design right through to final completion on site. We
own and operate a large fleet of the latest jacking systems, which are available on a rental or sub-
contract basis. Our services can be utilised effectively on a wide range of construction, upgrade and
maintenance projects for Bridges, Buildings, Refineries, Power Plants, Process Plants & Offshore
structures

Flexible service
We offer any combination of the following services to best suit the needs of each Client:
• Specialist sub-contractor for heavy lifting and skidding operations
• Jacking equipment rental with site supervisors and operators
• Permanent works design consultant
• Construction methodology consultant
• Temporary works design consultant
• Construction equipment designer and supplier
• Site supervision of specialist construction operations
For each service you can be assured that the full range of our skills and experience will be applied.
Our design services are backed by the practical knowledge of our site team and our site operations
are backed by the expert advice of our designers.

Proven products
As well as designing and supplying special ‘one off’ products such as bridge deck erection gantries
and refinery turnaround gantries we also have a range of standard products that are available for
hire or purchase:
• Strand jack systems
• Climbing jack and gripper jack systems
• Hydraulic ram systems
• General purpose jacking systems
In each case we will carefully evaluate the particular requirements of a project and recommend the
most effective system to be used. This will include an evaluation of the consequential benefits to
safety, cost and programme on the project as a whole for each type of system. It is our full
knowledge of the engineering, safety and commercial issues facing the project team that set us
apart from the competition. In 2000 the staff and business of Zalcon was acquired by DLT, and
Zalcon jacking systems are now offered under the name of DLT.

Specialist expertise
We have for many years been involved in the design and construction of major structures and have
developed the following areas of specialist expertise:
•Design and contracting for heavy lifting, lowering and skidding operations
• Erection engineering of suspension and cable stayed bridges
• Permanent works design/value engineering of bridges
• Design and supply of specialist gantry systems
• Design and supply of strand jack and climbing jack systems
• Design and detailing of steel frames structures

Quality Assured
Our engineering design and management system is accredited to BS EN ISO 9001:2000 and has
been written in-house by our own staff to specifically ensure a high and consistent standard of
service to our clients. All our jacking systems are inspected, serviced, tested and certified prior to
each use.

www.dormanlongtechnology.com
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Heavy lifting contracting services

We offer heavy lifting contracting services for the construction and refurbishment of bridges,
buildings, heavy process plant, petrochemical vessels and offshore structures. This service can
range from rental of jacking equipment with experienced supervisors to fully engineered site
operations undertaken as a sub-contract. Our experience and breadth of capabilities make us your
ideal site partner.
Recent examples of our contracting work include the following projects…..

Blast furnace re-lining, Taiwan

DLT were sub-contractors for installation of a new 40.75m high 3115 tonne
furnace line in Taiwan. Our scope included full engineering of all temporary
works required together with supply of jacking equipment and site labour to carry
out the work. The blast furnace was delivered to the site in 8 segments, weighing
up to 477 tonnes each, which were lifted and skidded into the furnace house
before being jacked vertically and aligned for welding. These operations were
carried out using a mix of strand jacks and climbing jacks

Bishop's bridge replacement, Paddington Station, London

DLT were sub-contractors for design, supply and operation of strand jack and
climbing jack systems for vertical lifting and horizontal skidding operations
required to replace the existing railway over-bridges with a new six lane
composite bridge. DLT were also responsible for conceptual and detailed design
of all construction methods, all of which take place within limited railway
possessions.

Sutong cable stayed bridge, China

DLT were sub-contractors for the lowering by strand jacks of a 3050 tonne steel
caisson to pier 4 pile cap and for supply and operation of 8 No 250 tonne
capacity deck erection gantries for lifting and aligning 108 steel orthotropic deck
sections weighing up to 450 tonnes each.

Carquinez suspension bridge, California

DLT were sub-contractors for erection of the 24 No. 700 tonne steel deck units,
which was carried out in 2003 using a system of computer controlled strand
jacks. The deck units were delivered directly to the bridge site by ship and lifted
into final position using 4 No 290 tonne capacity strand jacks mounted on the
deck units. DLT were also responsible for detailed construction engineering of
the main cables, deck hangers and steel orthotropic deck.

Formosa Plastics Plant, Taiwan

DLT were sub-contractors for the design, supply & operation of a 100m high
modular jacking tower system for the erection of 36 petrochemical vessels
ranging from 1120 tonne at 30m high through to 1450 tonne at 115 m high. We
were also responsible for engineering all of these operations.

Heat exchanger replacement, Indonesia

DLT were sub-contractors for the design, supply and operation of a 60 tonne
capacity gantry to replace 2 No 60 tonne heat exchangers from deep within a
steel framed structure on PT Peni’s site in Indonesia. Use of these purpose
designed gantries in place of conventional cranage avoided the need to
extensively dismantle the steel structure to gain access to the vessels, saving
time and money.

HAECO hanger roof lift, Hong Kong

DLT were sub-contractors for the design, supply and operation of a strand jack
lifting system to erect two pre-assembled roof sections, each weighing over 1000
tonnes.
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Consulting services
We offer a range of consultancy services for the design and construction of many types of structure,
including bridges, buildings, heavy process plant, petrochemical vessels and offshore structures.
We have particular expertise in the erection of long span suspension and cable stayed bridges, and
in the engineering of specialist modular construction operations such as heavy lifting, lowering and
horizontal skidding operations. All consultancy services are provided under our ISO 9001:2000
accredited quality management system and covered by professional indemnity insurance.

Recent examples of our consultancy work include the following projects……….

ChaoTianMen arch bridge, Chongqing, China

The ChaoTianMen arch bridge crosses the Yangtze river in the city of
Chongqin in South West China. It has a tied arch main span of 552m with
continuous side spans of 190m, and has been designed to resemble the
Sydney Harbour Bridge, completed by Dorman Long & Co. in 1932. DLT are
acting as consultant to the main contractor, 2nd Navigation engineering Bureau
and are responsible for developing and detailing the construction method to be
used. On completion this will be the longest arch span in the world, a record
currently held by the Lupu bridge in Shanghai (550m).
Boyne cable stayed bridge, Ireland
DLT were responsible for the design of the superstructure, as an alternative to
the client’s design, detailed design of the erection methods for all elements of
the deck and for supply and operation of the strand jacking systems used to
launch the deck into final position.

Heathrow Airport, New Terminal 5, UK

DLT were responsible for the detailed erection engineering for the 18,500
tonne steel roof of the new main core terminal building and a 1000 tonne air
traffic control tower. Both are being fabricated off site and erected on site using
strand jack lifting systems.

New Wembley National Stadium, UK

DLT were responsible for the detailed erection engineering for the 26,000
tonnes of structural steel, including stands, cable suspended roof and main
arch structures. The 1,490 tonne main arch was assembled flat and rolled up
into position using strand jacks. We were responsible for engineering and
supervising this operation.

Tuti suspension bridge, Khartoum

DLT are responsible for the permanent works design and erection engineering
for this landmark structure in the centre of Khartoum. The bridge has a main
span of 210m and has been designed for construction by local labour.

Popolopen footbridge, NY, USA

DLT were responsible for the detailed design of this 140m span suspension
footbridge on the Appalachian trail. Innovative design and use of composite
materials resulted in this aesthetic and durable structure.

www.dormanlongtechnology.com
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Jacking systems
DLT design and supply a range of specialist jacking systems for heavy lifting operations. Our jacking
systems were formerly sold under the name of Zalcon, which has since become part of DLT. Our
designs are based on many years of experience of using the equipment ourselves to carry out many
of the heavy lifting operations featured in this brochure. All DLT jacking systems are designed for
reliability, ease of handling and maintenance in the field and are tested and independently certified
prior to leaving our works. Our systems are used around the world by many of the top international
contractors. If you have a heavy lifting operation to carry out we will be pleased to provide expert
advice on the most appropriate system for your needs. If required, we can also engineer and
supervise the heavy lift operation for you and train your staff in the use and maintenance of our
equipment. Please see our separate brochure for more details of our jacking systems.

DLT Strand Jack systems

We offer a range of strand jacks, hydraulic power packs and control systems to cater for all
requirements and will be happy to advise on the right system for your project. Our strand jacks
incorporate the latest safety features and range from light DL-S15 (15 tonne lifting capacity per jack)
‘super tirfors’ through to our DL-S775 (775 tonnes lifting capacity per jack) and can be safely used in
combinations of up to 40 jacks by a single operator using our DL-P40 computer control system.

DLT Climbing Jack systems

Climbing jacks offer an attractive alternative to strand jacks where it is desirable to keep the load path
beneath the item being lifted. We have used climbing jack systems ourselves for lifting bridge
structures, roofs and petrochemical vessels and find them to be a rugged and useful addition to our
fleet. Sometimes referred to as ‘Koala bear jacks’, they work by climbing a square compression bar
that transfers the lift load down to its base. Each jack can have a lifting capacity of between 100 and
450 tonnes. The square bar is restrained from compression buckling by light restraints, which can be
fitted to building columns, bridge piers etc. Safety, power and control systems are as offered for our
strand jacks

DL-P40 computer control screen

for both strand jacks & climbing jacks
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Reference projects - Bridge construction

We have considerable experience in the design and construction of all types of bridges and have
been involved in creating many of the world’s best known bridges. Whether you are looking for a
bridge designer or specialist contractor, DLT are able to offer a comprehensive service.

Recent examples of our work include……….

ChaoTianMen arch bridge, Chongqing, China

The ChaoTianMen arch bridge crosses the Yangtze river in the city of Chongqing
in South West China. It has a tied arch main span of 552m with continuous side
spans of 190m, and has been designed to resemble the Sydney Harbour Bridge,
completed by Dorman Long & Co. in 1932. DLT are acting as consultant to the
main contractor, 2nd Navigation engineering Bureau and are responsible for
developing and detailing the construction method to be used. On completion this
will be the longest arch span in the world, a record currently held by the Lupu
bridge in Shanghai (550m).
Orinoco River Second Crossing, Venezuela
At over 3km long and with two cable stay spans of 310m, this project provided
many engineering challenges. The steel box girder deck for the 60m approach
spans was launched in pre-assembled units of up to 2413 tonnes. The steel box
girder deck of the two cable stay main spans was erected by balanced cantilever
in 250 tonne segments. DLT were responsible for supply and operation of the
strand jack systems for launching of the approach spans and for lifting & skidding
of the main span deck units.

Boyne cable stayed bridge, Ireland

DLT were responsible for the design of the superstructure, as an alternative to
the client’s design, detailed design of the erection methods for all elements of the
deck and for supply and operation of the strand jacking systems used to launch
the deck into final position.

Carquinez suspension bridge, California

DLT were responsible for all aspects of construction engineering for the bridge
deck, main cables and hangers for this 728m span suspension bridge. We also
undertook the sub-contract to erect the 24 No. 700 tonne steel deck units, which
was carried out using strand jacks.

Bishop's bridge replacement, Paddington Station, London

The existing 3 span masonry bridge and steel truss span which cross 15 rail lines
at the entrance to London's Paddington Station were replaced in 2006 with a new
six lane composite bridge. The masonry spans were demolished and the 941
tonne truss bridge has lifted 9.8m to allow assembly and incremental launching of
the new 2500 tonne bridge deck. DLT were responsible for conceptual and
detailed design of all construction methods and supply and operation of all
jacking systems for the lifting and launching operations, all of which took place
within limited railway possessions.

Sutong cable stayed bridge, China

DLT were sub-contractors for the lowering by strand jacks of a 3050 tonne steel
caisson to pier 4, from its assembly position above water level to its final
submerged position. The operation was carried out in October 2004 using 16 No
DL-S418 strand jacks controlled and synchronised by a single operator using a
DL-P40 computer control unit. With a 1088m main span, the Sutong bridge will be
the largest cable stay bridge in the world when completed.

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Shibanpo bridge, Chongqing, China

The Shibanpo bridge is a multi-span in-situ concrete box girder bridge with a
main span of 330m. The central 108m of the main span was designed as a steel
box girder to save weight, which was delivered to site in 3 pieces - a 1325 tonne,
103m centre section and two 100 tonne 2.5m long steel transition pieces that
connect it to the concrete deck at either end. All three units were erected by DLT
using strand jacks. 8 No DL-S418 strand jacks will be used for lifting, monitored
and controlled by a single operator using the DL-P40 computer control system.
The three lifts were completed in July 2006..

Yangluo suspension bridge, China

DLT have been appointed as construction engineers to the main contractor,
CHEC.2nd Navigation Engineering Bureau for erection of the cables on this
1280m span suspension bridge across the Yangtze river near Wuhan. Our work
includes concept design of the walkways, tower top steelwork & PPWS cable
erection.

El Damar bridge, Sudan

El Damar Bridge will carry the new road currently being constructed between
Atbara and Merowie in Sudan, over the River Nile, close to the town of El Damar.
The Nile is over 850m wide at the bridge location, divided into two channels by an
island midway between the banks. The deck will comprise 21 No. 40.9m span
precast, post-tensioned T girders with insitu reinforced concrete slab. It will be
supported on cross beams carried by circular reinforced concrete column bents
and piled foundations. DLT are consultants for conceptual and detailed design of
the bridge & foundations
Tuti suspension bridge, Khartoum
DLT are responsible for the permanent works design and erection engineering for
this landmark structure in the centre of Khartoum. The bridge has a main span of
210m and has been designed for construction by local labour.

Popolopen footbridge, NY, USA

DLT were responsible for the detailed design of this 140m span suspension
footbridge on the Appalachian trail. Innovative design and use of composite
materials resulted in this aesthetic and durable structure.

Gatwick airport passenger bridge erection gantries, UK

The new airport passenger bridge at Gatwick Airport, UK, spans 128m across a
busy taxi way. To reduce disruption to the airport, the bridge was assembled off
site, complete with cladding and internal fit out and then transported and erected
in a 10 day closure of the taxi-way. DLT were responsible for the detailed design
of a pair of 1640 tonne capacity gantries for lifting the completed bridge into final
position, weighing 2,660 tonnes. The bridge was lifted using 8 No 410 tonne
capacity strand jacks and the gantries were constructed from a modified
proprietary jacking tower system.
Runyang suspension bridge, China
DLT were responsible for the design, supply and commissioning of 4 No 370
tonne capacity deck erection gantries for this 1490m main span suspension
bridge. These gantries walk the main cables and work in pairs to erect steel deck
units weighing up to 470 tonnes each. The gantries can be self erected onto the
main cables and are easily adapted for future projects with different cable centres
and diameter.
 Page 9

Sheikh Khalifa Bin Salaman Causeway Bridge, Bahrain

DLT were responsible for erection engineering of the bridge steel structure,
involving offsite assembly of the 3000 tonne main span, transport to site and
lifting in one piece into final position using 8 No 500 tonne capacity strand jacks.

Jiangyin suspension bridge, China

DLT were responsible for detailed erection engineering, heavy lifting equipment
supply and site supervision for deck erection on this 1385m main span
suspension bridge.

Tsing Ma suspension bridge, Hong Kong

DLT were responsible for detailed erection engineering, heavy lifting equipment
supply and site supervision for deck erection on this 1377m main span
suspension bridge.

A2/M2 Medway Bridge, Kent, UK

DLT were responsible for the design, supply and operation of a 800 tonne
capacity climbing jack system for the lifting and lowering of temporary formwork
support trusses for the construction of 80m long in-situ post tensioned concrete
approach spans.

Tamar suspension bridge strengthening & widening, UK

DLT were responsible for value engineering of the permanent strengthening&
widening works and conceptual and detailed design of all erection and demolition
methods and related temporary works for carrying out this upgrade to the existing
335m span suspension bridge.

Lions Gate suspension bridge deck replacement, Vancouver

DLT were responsible for supply & operation of a strand jacking system to carry
out replacement of the complete bridge deck in 54 sections, each within a 10
hour overnight closure of the bridge. 4 No DL-S60 strand jacks (plus 2 No spare
jacks) with power and control system for a lifting speed of 60 metres per hour
were supplied to the main contractor, American Bridge.

www.dormanlongtechnology.com
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Reference projects - Buildings & structures

We have considerable experience in the construction of major building structures using modular
construction techniques for early completion. Maximising offsite pre-assembly allows the
foundations to be installed in parallel with the structure and many elements of the structure to be
assembled offsite at the same time. The techniques of transporting and erecting large/heavy sub
assemblies are key to the success of these projects.

Recent examples of our work include……….

Heathrow Airport, New Terminal 5, UK

DLT were responsible for the detailed erection engineering for the 18,500 tonne
steel roof structure of the new main core terminal building, and for a 1100 tonne
air traffic control tower. Both were fabricated off-site and erected on-site using
strand jack lifting systems. The roof box girders, purlins and cladding to the core
terminal building roof was erected in 6 No 2,000 tonne lifts. The control tower
was pre-assembled off-site into 7 fully complete modules and then assembled
on-site using a unique vertical jacking technique.

New Wembley National Stadium, UK

DLT were responsible for the detailed erection engineering for the 26,000 tonnes
of structural steel, including stands, cable suspended roof and main arch
structures. The 1,490 tonne main arch was assembled flat and rolled up into
position using strand jacks. We were responsible for engineering and supervising
this operation.

Hong Kong Convention & Exhibition Centre.

DLT were responsible for erection engineering, heavy lifting equipment supply &
operation for the erection of an 8000 tonne prefabricated roof structure and a
5,500 tonne link bridge. The roof structure was fabricated and assembled in the
Philippines into modules weighing up to 460 tonnes each, which were then
shipped to the site for lifting and skidding into final position. The link bridge was
erected piece small by a stiff leg derrick mounted on a purpose made skid track.

HAECO hanger roof lift, Hong Kong

DLT were responsible for the design, supply and operation of a strand jack lifting
system together with associated erection engineering to lift 2 No pre-assembled
roof sections, each weighing over 1000 tonnes. Each section of roof was lifted
with 9 No DL-S185 strand jacks. Temporary works for the lift comprised 3 No
300 tonne capacity jacking towers, plan bracing to stabilise the roof and a guide
track against the concrete core structure.

HQ1 Building, London

DLT were responsible for detailed connection design and erection engineering of
the 6,600 tonnes of steel frame to this 16 storey office block. This included heavy
lifting of a 650 tonne module which was built on a lower floor and then raised
30m to the 16th floor. DLT were also responsible for supply and operation of the
strand jack system to carry out this lift, using 4 No DL-S185 strand jacks

Virgin Atlantic Airways hanger roof lift, London

DLT were responsible for the detailed erection engineering for the lifting by
strand jacks of an 800 tonne roof truss for this aircraft maintenance hanger at
Heathrow Airport. The roof structure was assembled at ground level and then
lifted using strand jacks mounted on the top of the permanent columns, which
were stabilised by rented proprietary towers that were anchored down to the
permanent foundations.
 Page 11

Link bridges, Hong Kong

DLT were responsible for the design, supply and operation of a strand jack
heavy lifting & horizontal skidding system for the erection of two 1100 tonne pre-
assembled link bridges in Hong Kong for main contractor, Gammon-Skanska.

Canary Wharf Tower, London

DLT were responsible for the detailed connection design and erection
engineering of the 25,700 tonne steelwork frame for this 50 story tower block.

HSBC Bank, London

DLT were responsible for the detailed connection design and erection
engineering of the 12,000 tonne steelwork frame for this 43 story tower block.

Bank of America building, London

DLT were responsible for the detailed connection design and erection
engineering of the 6,400 tonne steelwork frame for this 16 story office block.

Clifford Chance building, London

DLT were responsible for the detailed connection design and erection
engineering of the 12,300 tonne steelwork frame for this 34 story tower block.

McGraw-Hill building, London

DLT were responsible for the detailed connection design and erection
engineering of the 6,300 tonne steelwork frame for this 12 story office block.

Morgan Stanley building, London

DLT were responsible for the detailed connection design and erection
engineering of the 2,200 tonne steelwork frame for this 8 story office block

Cairns Convention Centre Phase II, Australia.

The roof to this convention centre is constructed from a complex series of curved
V shaped steel trusses that work with a plan tie system in the finished state to
provide a rigid and stable structure. To reduce the roof erection cost and
programme, the roof was assembled in fully clad panels adjacent to the site and
erected onto temporary supports within the building. We were responsible for the
detailed erection engineering of the roof, including all temporary supports and
stability bracing, which was required to withstand cyclone wind loads at any
erection stage

www.dormanlongtechnology.com
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Reference projects - Heavy lifting

The Dorman Long & Zalcon names are synonymous with heavy lifting projects around the world for
bridges, major buildings, refineries and offshore structures. The heavy lift business of Zalcon was
acquired by DLT in 2000, together with the transfer of all staff and equipment. Our strength in this
market is our engineering ability, provided by over 30 technical staff including over 20 fully qualified
engineers specialising in this field. No other heavy lifting company in the world has this level of in-
house engineering capability. We are not only experts in heavy lifting, but also have considerable
experience in the design and construction of most of the structures we are erecting. We are
therefore able to analyse the whole construction problem to arrive at the most economic overall
construction solution for the project, including re-design of the permanent works if required. We own
and operate a large fleet of the latest jacking systems, which are available on a rental or sub-
contract basis.

We have been involved in many heavy lifting and load out/launching operations over the past 25
years, as heavy lift sub-contractors and/or heavy lift design engineers. Our heavy lift design
expertise is such that we are regularly employed by other heavy lift contractors to carry out the
detailed engineering on their projects and by Client bodies to independently audit the work of heavy
lift sub-contractors.

Project list : Heavy lift sub-contractor / equipment rental + site operation & supervision
Project Description No & max wt Dist. Year
Sutong bridge, China Lifting of steel deck segments 84 x 450 te 60m 2006-7
Shibanpo bridge China Lifting of 103m long steel box girder 1x 1325 te 50m 2006
Blast furnace, Taiwan Lifting of furnace sections, 8x418 te strand jacks 8x 448 te 30m 2005
Bishop's bridge, UK Launching of bridge deck, 4 x 418 te strand jacks 1x 2500 te 105m 2005
FHIC plant, Taiwan Lifting of heavy vessels, 2-4 x 580 te strand jacks 16 x 1300 te 120m 2005
Orinoco bridge, Ven. Launching of bridge deck, 2 x 185 te strand jacks 8x 2400 te 1530m 2004-5
Orinoco bridge, Ven. Lifting of deck units, 2 x 185 te strand jacks 44 x 250 te 40m 2004-5
Sutong bridge, China Lowering steel caisson, 16 x 418 te strand jacks 1 x 3,050 te 7m 2004
Bishop's bridge, UK Lifting steel bridge, 4 x 418 te strand jacks 1x 941 te 10m 2004
Carquinez bridge, USA Lifting steel deck units, 4 x 290 te strand jacks 24 x 700 te 50m 2003
Wembley arch, UK Rotation of steel arch, 20 x 418 te strand jacks 1 x 2,830 te 260m 2004
Runyang bridge, China Lifting of steel deck units, 2 x 185 te strand jacks 47 x 460 te 50m 2003
Runyang bridge, China Self erection of gantries, 4 x 60 te strand jacks 1x 150 te 180m 2003
Container crane,China Lifting of crane superstructure, 8x185 te strand jacks 10 x 900 te 50m 2003
Colne Barrier, UK Lifting of flood defence gates, 2 x 105 te strand jacks 1x 180 te 0.5m 2003
HQ1 building, London Lifting of truss & hung floors, 4 x 185 te strand jacks 1x 650 te 30m 2003
Boyne bridge, Ireland Launch of deck, 10x185 te + 2x580 te strand jacks 1x 1400 te 180m 2002
A2/M2 bridge, UK Lifting of formwork truss, 8 x 125 te climbing jacks 8x 700 te 20m 2002
Lions Gate bridge, BC Lifting/lowering of deck sections, 4x60 te strand jacks 54x 160 te 50m 2000-1
FPSO Pontoon, Korea Load out of FPSO pontoon, 4 x 580 te strand jacks 1 x 14,500te 125m 1999
Dang San br. Korea Lifting of steel deck girders, 8 x 185 te strand jacks 8 x 1,000 te 40m 1999
Dang San br. Korea Load out of steel deck girders, 4 x 105 te strand jacks 8 x 1,000 te 150m 1999
Retail bridges, HK Lifting of steel bridge, 8 x 185 te strand jacks 2 x 1,100 te 24m 1998
FHIC plant, Taiwan Lifting of heavy vessels, 2-4 x 580 te strand jacks 36 x 1,450 te 120m 1996-9
Silo roof, India Lifting of silo roof, 12 x 105 te strand jacks 1x 650 te 28m 1998
Hanger roof, HK Lifting of HAECO hanger roof, 9 x 185 te strand jacks 2 x 1,000 te 30m 1996
HKCEC roof, HK Lifting of roof truss panels, 4 x 185 te strand jacks 8x 460 te 40m 1995-6
HKCEC roof, HK Skidding of roof truss panels, 2 x 60 te gripper jacks 8x 460 te 80m 1995-6
Power plant, Pakistan Lifting/installation of generator, 4x105 te strand jacks 1x 325 te 20m 1995
 Page 13

Tsing Ma bridge, HK Lifting of main span deck units, 4x418te strand jacks 50 x 1,000 te 70m 1995-6
Tsing Ma bridge, HK Lifting of side span deck units, 4 x 418te strand jacks 2 x 1,450 te 60m 1994
Tsing Ma bridge, HK Skidding of side span deck units, 4x15te strand jacks 2 x 1,450 te 40m 1994
Power plant, HK LIfting of HRSG modules, 6 x 105 te strand jacks 12 x 321 te 15m 1994
Power plant, Korea Lifting/installation of generator, 4x105 te strand jacks 1x 350 te 15m 1994
Shell Dunbar Jacket Load out of jacket, 4 x 418 te strand jacks 1 x 8,000 te 250m 1994
Marathon E.B. platform Load out of platform, 4 x 418 te strand jacks 1 x 9,800 te 280m 1993
Shell Nelson platform Load out of platform, 4 x 418 te strand jacks 1 x 8,600 te 330m 1993
B.P. Bruce deck Load out of deck, 4 x 418 te strand jacks 1 x 10,000te 180m 1992
B.P. Bruce platform Load out of platform, 4 x 418 te strand jacks 1 x 8,900 te 320m 1992

Project list : Heavy lift engineering by DLT for operations carried out by other heavy lift companies
Project Description No & max wt Dist. Year
Jamnagar refinery Lifting of splitter column, 4 x 450 te strand jacks 1x 1499 te 100m 2005
Burghausen refinery Lifting of splitter column, 2 x 450 te strand jacks 1x 605 te 88m 2005
Heathrow T5, UK Lifting of steel roof modules, 16 x 185 te strand jacks 6 x 2,000 te 30m 2004-5
Heathrow T5, UK Lifting of new control tower, 3 x 580 te strand jacks 1 x 1,100 te 90m 2004-5
Airport bridge, UK Lifting of pedestrian bridge, 8 x 418 te strand jacks 1 x 2,660 te 22m 2004
Petro-Canada, Canada Lifting of 2 No reactors, 2 x 450 te strand jacks 2x 540 te 38m 2004
Goliath crane, Sweden Lowering of crane cross girder, 8x480 te strand jacks 1 x 4,200 te 110m 2003
Qatar refinery, Qatar Lifting of 2 No reactors, 4 x 750 te strand jacks 2 x 2,100 te 60m 2005
s. Khalifa bridge, UAE Lifting of steel arch bridge 1 x 3000 te 30m 2003
Yoho platform,Malaysia Incremental lifting of topsides, 12x580 te strand jacks 1 x 3,800 te 20m 2003
Chemical plant, China Lifting of petrochemical vessel, 2x650 te strand jacks 1x 763 te 92m 2003
Virgin hanger, UK Lifting of hanger roof truss, 8 x 185 te strand jacks 1x 800 te 40m 2001
Beaumont refinery,USA Lifting of reactor, 4 x 580 te strand jacks 1 x 1232 te 39m 2000
Tema refinery, Ghana Lifting of petrochemical vessels, 2x290te strand jacks 3x 395 te 72m 2000
PHPV refinery, India Lifting of vacuum column, 2 x 290 te strand jacks 1x 560 te 60m 2000
Sarroch refinery, Sard. Lifting of reactors, 1 x 580 te strand jack 2x 500 te 24m 1999
Power station, UK Lifting of boiler modules, 1 x 105 te strand jack 36 x 65 te 16m 1999
Brent Spar, Norway Lifting of Brent Spar sections, 4 x 600 te strand jacks 4 x 2,214 te 1m 1999

www.dormanlongtechnology.com
Page 14

Reference projects – Erection Gantries

There are many situations where conventional cranage is not the best option for lifting or moving
heavy items. The load and reach may be outside the capacity of available cranes or there may not
be space to assemble/stand a heavy crane. In these situations it can be economic to use a specially
designed piece of heavy lifting equipment. We have encountered many such construction projects
and as a result have developed a skill in the design and supply of purpose built mechanised erection
systems, including bridge deck erection gantries, component handling systems and heavy lifting
towers. If you have a particular need to handle large or heavy items on your site we will be pleased
to advise on the most economic overall solution for your project.

Recent examples of our work include the following projects........

Sutong cable stayed bridge, deck erection gantries
With a main span of 1088m the Sutong Cable stayed bridge will be the longest
span cable stayed bridge in the world when it is opened in 2007. DLT have been
awarded the sub-contract by 2nd Navigation Engineering Bureau to design and
supply the eight deck erection gantries that will be used to erect the 84 No steel
orthotropic deck segments, each weighing up to 450 tonnes.

DL-SE 900/33 span erector for China high speed rail viaducts
The DL-900/33 span erector has recently been designed by us to erect standard
900 tonne precast concrete deck girders on the planned high speed rail lines that
will be built to link many of the main cities in China over the next few years. The
gantries will be manufactured in China by our partner, Wuhan Bridge Machinery
Co. The DL-SE 900/33 has been designed for quick and simple operation and is
capable of erecting one span every 3.5 hours. The gantry can be launched
forward or backwards, can easily be turned through 180 degrees to reverse the
construction direction and utilises the delivery trailer to move between separate
sections of viaduct without the need to dismantle and re-assemble the gantry.
Runyang suspension bridge, China. Deck erection gantries.
DLT were responsible for the design, supply and commissioning of 4 No 370
tonne capacity deck erection gantries for this 1490m main span suspension
bridge. These gantries walk the main cables and work in pairs to erect steel deck
units weighing up to 470 tonnes each. The gantries can be self erected onto the
main cables and are easily adapted for future projects with different cable centres
and diameter.

Tsing Ma suspension bridge, Hong Kong. Deck erection gantries

DLT were responsible for the detailed design of the 4 No deck erection gantries
that were used to erect the 1000 tonnes deck units of this 1377m span
suspension bridge. We also supplied the strand jack systems used by the
gantries for lifting the deck units and for gantry movement along the cables.

Formosa Plastics Plant, Taiwan. Jacking tower system.

DLT were responsible for the design, supply & operation of a 100m high modular
jacking tower system for the erection of 36 petrochemical vessels ranging from
1120 tonne at 30m high through to 1450 tonne at 115 m high.
 Page 15

Gatwick airport passenger bridge erection gantries, UK

The new airport passenger bridge at Gatwick Airport, UK, spans 128m across a
busy taxi way. To reduce disruption to the airport, the bridge was assembled off
site, complete with cladding and internal fit out and then transported and erected
in a 10 day closure of the taxi-way. DLT were responsible for the detailed design
of a pair of 1640 tonne capacity gantries for lifting the completed bridge into final
position, weighing 2,660 tonnes. The bridge was lifted using 8 No 410 tonne
capacity strand jacks and the gantries were constructed from a modified
proprietary jacking tower system.

2500 tonne strand jack tower system, China

DLT were responsible for the conceptual and detailed design of this 2500 tonne
lifting capacity modular strand jack tower system, specifically designed for the
Chinese refinery construction market. The tower system is owned and operated
by the No 4 Construction company of SINOPEC and has many new features
including self-erection and luffing under full load.

Westrail track slab handling gantries, Hong Kong

DLT were responsible for the design and supply of 2 No track slab handling
gantries for the West Rail project. The gantries was capable of handling two 6
tonne track slabs at a time and were designed to run along the track derailment
kerbs.

Heat exchanger replacement gantry, Indonesia

DLT were responsible fore the design, supply and operation of a 60 tonne
capacity gantry to replace 2 No 60 tonne heat exchangers from deep within a
steel framed structure on PT Peni’s site in Indonesia. Use of these purpose
designed gantries in place of conventional cranage avoided the need to
extensively dismantle the steel structure to gain access to the vessels, saving
time and money.

Dismantling of the Brent Spar oil storage platform

DLT were responsible for the design of a 2300 tonne lifting capacity lifting gantry
for handling cut sections of the Brent Spar as it was decommissioned in a
Norwegian fjord in 1999. The gantry used 4 No 580 tonne capacity strand jacks
for lifting and a gripper jack system for longitudinal movement over the
decommissioning barge. The legs and cross beams of the gantry structure were
made from a proprietary tower system which were connected and braced using
purpose designed steelwork.

Bridge deck erection gantries for pre-cast concrete viaducts

DLT are experienced in the design of various bridge deck erection gantries. This
picture shows our tender design for a self launching bridge deck erection gantry
for erection of precast concrete segments on the 75m approach spans to the
Sutong cable stayed bridge. The gantry was designed to handle precast concrete
segments weighing up to 160 tonnes each, which were erected by the balanced
cantilever method, and to suspend a half span of segments adjacent to deck
movement joints weighing up to 1100 tonnes. The gantry was designed to handle
deck longitudinal gradients of +/- 3%, deck plan minimum curvature of 950m and
to skid sideways to erect adjacent box girders.

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Page 16

Reference projects - Refinery construction

DLT are experts in the erection of heavy vessels using conventional cranage and specialist jacking
systems. We have extensive knowledge of all available equipment and are able to advise on the
most practical, economic and safe solution for your project. We have been involved in the
engineering of many heavy lifting schemes inside refineries and the design and supply of specialist
heavy lifting equipment to carry out these operations. We carry out this work for ourselves and for
other heavy lifting companies, as well as acting as advisors to Client organisations.

Recent examples of our work include………

Formosa Plastics Plant, Taiwan

DLT were responsible for the design, supply & operation of a 100m
high modular jacking tower system for the erection of 36
petrochemical vessels ranging from 1120 tonne at 30m high
through to 1450 tonne at 115 m high.

2500 tonne strand jack tower system, China

DLT were responsible for the conceptual and detailed design of this
2500 tonne lifting capacity modular strand jack tower system,
specifically designed for the Chinese refinery construction market.
The tower system is owned and operated by the No 4 Construction
company of SINOPEC and has many new features including self-
erection and luffing under full load.

Heat exchanger replacement, Indonesia

DLT were responsible fore the design, supply and operation of a 60
tonne capacity gantry to replace 2 No 60 tonne heat exchangers
from deep within a steel framed structure on PT Peni’s site in
Indonesia. Use of these purpose designed gantries in place of
conventional cranage avoided the need to extensively dismantle the
steel structure to gain access to the vessels, saving time and
money.

Heavy vessel erection projects using strand jack tower systems.

Detailed engineering carried out by DLT.

Project Description No & max wt Dist. Year

Jamnagar refinery Lifting of splitter column, 4 x 450 te strand jacks 1x 1499 te 100m 2005
Burghausen refinery Lifting of splitter column, 2 x 450 te strand jacks 1x 605 te 88m 2005
Qatar refinery, Qatar Lifting of 2 No reactors, 4 x 750 te strand jacks 2 x 2,100 te 60m 2005
Chemical plant, China Lifting of petrochemical vessel, 2x650 te strand jacks 1x 763 te 92m 2003
Beaumont refinery,USA Lifting of reactor, 4 x 580 te strand jacks 1 x 1232 te 39m 2000
Tema refinery, Ghana Lifting of petrochemical vessels, 2x290te strand jacks 3x 395 te 72m 2000
PHPV refinery, India Lifting of vacuum column, 2 x 290 te strand jacks 1x 560 te 60m 2000
Sarroch refinery, Sard. Lifting of reactors, 1 x 580 te strand jack 2x 500 te 24m 1999
 Page 17

Reference projects - Offshore construction

DLT have been involved in a number of offshore construction projects, mainly in the skidding and
lifting of heavy sub-assemblies within construction yards. We are able to design, supply & operate
heavy lifting systems to carry out these operations together with full design of all temporary &
strengthening works required. Recent examples of our offshore work include……….

Load out of FPSO pontoon, Korea

DLT were responsible for the design,
supply & operation of a strand jack
system to load out a 14,500 tonne
FPSO pontoon onto a delivery ship, for
main contractor Hyundai. The deck
was moved 125 metres using four 580
tonne capacity strand jacks

Offshore load outs in Scotland

DLT (Zalcon) were responsible for the
design, supply & operation of strand jacks
systems for the load out of the following
offshore structures in the 1990’s

B.P. Bruce Jacket (above) 8,900 tonnes 320m load out

B.P. Bruce Deck 10,000 tonnes 180m load out
Shell Nelson Jacket 8,600 tonnes 330m load out
Marathon East Brae Jacket 9,800 tonnes 280m load out
Shell Dunbar Jacket 8,000 tonnes 250m load out

Dismantling of the Brent Spar oil storage platform

DLT were responsible for the design of a 2300 tonne lifting capacity
lifting gantry for handling cut sections of the Brent Spar as it was
decommissioned in a Norwegian fjord in 1999. The gantry used 4 No
580 tonne capacity strand jacks for lifting and a gripper jack system
for longitudinal movement over the decommissioning barge. The legs
and cross beams of the gantry structure were made from a
proprietary tower system which were connected and braced using
purpose designed steelwork.

Replacement of thrusters on semi-

submersible drilling platform
DLT were responsible for the design,
supply & operation of a 180 tonne
capacity strand jack system for the
removal and replacement of thrusters
from the underside of the rig, for
Stenna Offshore Ltd.

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Page 18

Project sheet - Boyne cable stayed bridge, Ireland

The Boyne bridge is a new motorway crossing of the river Boyne in Ireland, some 30 miles north of
Dublin. DLT were responsible for the design of the superstructure, as an alternative to the client’s
design, detailed design of the erection methods for all elements of the deck and for supply and
operation of the strand jacking systems used to launch the deck into final position. The re-designed
bridge has a continuous composite deck with spans or 43.5m, 170m, 45m, 40m and 25m. The deck
construction comprises two primary outer longitudinal girders with multiple transverse girders
supporting a composite concrete deck. In the 170m main span the deck is supported by twenty eight
fanned cables, fourteen on each side of the deck, which connect to a 95m high reinforced concrete
‘A’ frame pylon which is anchored by cables to the abutment behind.

The site is of special historic interest and working in the river was prohibited. A novel solution was
devised by DLT at tender stage to overcome this constraint. The 113.5m long main and back spans
were assembled behind the south abutment and then launched forward into final position. To
support the deck during launching an arrangement of continuously adjusting strand jacks was used
as shown below. Precise calculation of the deck geometry and strand jack forces at all stages was
required to enable site operations to be properly controlled. As far as we are aware, this is the only
cable stay bridge in the world to have been erected in this way and should prove to be a useful
method to employ on other projects where ground access is limited.
 Page 19

Project sheet - Carquinez suspension bridge, California

The recently completed Carquinez Suspension bridge was built by a joint venture between FCI-
Constructors and Cleveland Bridge under a US$200m contract. DLT were responsible to the JV for
carrying out all erection engineering for the steel deck, main cables and deck hangers, and were
also sub-contractor for erecting the 24 No, 700 tonne steel deck units.

The deck units were fabricated in Japan and

transported to site in specially converted ships, 8 deck
units per shipment. The ships were able to travel to the
bridge site and were moored under the main cables for
lifting of the deck units into final position.
Each deck unit was lifted by 4 No 300 tonne capacity
strand jacks mounted in specially designed frames
connected to the top of the units. Each lift took one shift
to complete

All lifting operations were controlled by a computer that

monitored the load and distance travelled in each jack.
Using this system it was possible to correct the jacking
system during lifting to keep the deck units level and the
jack loads equally balanced.
About half of the deck units could not be delivered by
the ships directly under their final position due to
obstructions at water level and had to be lifted up off the
ship and then swung sideways, often requiring many
successive swinging operations. The deck unit shown
on the left was swung over 50m into final position using
two sets of 4 strand jacks mounted on frames pinned to
the deck to allow rotation

All 24 deck units were lifted in a period of 79 days. This

picture shows the last deck unit being lifted into final
position

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Page 20

Project sheet - Orinoco River Second Crossing, Venezuela

The second crossing of the Orinoco River near Puerto Ordaz in Venezuela is 3.12 km long and has 2
No 300m cable stay spans over the navigation channels. The bridge has a steel box girder deck along
its full length which is being erected by launching in the North & South approach spans and by a
combination of lifting and skidding in the main cable stayed spans and 4 x 60m central spans. Deck
erection commenced in January 2005 and was completed in June 2006. All these deck erection
operations were performed using strand jacks systems supplied, maintained and operated by DLT,
under sub-contract to the main contractor Construtora Norberto Odebrecht S.A.

Approach spans
The steel deck for the approach spans was divided into 8 No sections, of up to 300m long and
weighing up to2400 tonnes, for assembly behind the North & south abutments and for launching
separately into final position - a launch distance of up to 1.53 km. A pair of DL-S185 strand jacks, 185
MT capacity each and powered form a single DL-L30/2/E power pack, were connected to each deck
section (see below) and pulled along 120m long static strand cables anchored to the top of forward
piers to launch the deck sections forward at a speed of 17 m/hr. After each 120m of launch (2 x 60m
spans) the two strand cables were winched forward two spans to allow the launch to continue. The two
span launch of 120m was generally carried out in a single 10 hour shift.

Central 4 x 60m spans

The deck of the 4 No 60m central spans between the two cable stayed spans were erected in
segments of 250 tonnes which were delivered by barge to the foot of the main pylons and then lifted
onto temporary skid track trusses before being moved into final position, aligned and then welded
together to form the finished deck. The cantilever gantry show below was used to lift these deck
segments from the delivery barges and transfer them to the temporary skid track. 2 No DL-S185 strand
jacks were used for lifting, powered from a single DL-L30/2/E power pack for a lift speed of 17 m/hr,
and 4 No DL-S60 strand jacks were used for horizontal skidding of the fully loaded lifting girder. The
DL-S60 strand jacks were mounted onto the lifting girder (see below right) and pulled in either direction
along a static strand. They each took a 15 l/min feed from the DL-L30/2/E power pack for a movement
speed of 15 m/hr.
 Page 21

Cable stayed spans

The deck of the two 300m cable stayed spans was erected in 12m long 250 tonne segments by
specially designed self launching deck erection gantries as shown below. Each gantry used 2 No DL-
S185 strand jacks for lifting powered from a single DL-L30/2/E power pack for a lift speed of 17 m/hr.
Each deck unit was delivered by barge into position for lifting and was then lifted to just above final
level using the DL-S185 strand jacks. Deck units were lifted with a nominal 500mm gap to the
previously erected deck unit. The strand jacks and deck unit were then skidded together by hydraulic
rams to close and align the deck joint. Finally, the hydraulic bleed system incorporated in the DL-S185
strand jacks was used to very slowly lower the deck unit to final alignment to within +/- 1mm tolerance.
The deck unit was then held on the strand jacks whilst the joint was bolted and welded.

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Page 22

Project sheet - Bishop's bridge replacement, Paddington Station, UK

The Paddington LTVA project included the replacement an existing Bishops Bridge over the entrance
to Paddington Station, London, with a new wider structure to improve access to the station. The old
bridge consisted of a 60m span truss over 10 tracks, a 3 span structure over a further 5 tracks and a
series of short spans crossing open ground and the Grand Union Canal. The construction method for
the new bridge, chosen to minimise disruption and risk to rail traffic, involved lifting the truss span on
jacking towers to allow replacement of the substructures and launching of the new bridge deck
underneath. The existing bridge, weighing 941 tonnes, was lifted in August 2004 using 4 No DL-S418
strand jacks (see photo below) and the new deck was launched in beneath it in 2005.

Headroom and highway alignment constraints dictated the new superstructure form of multiple
variable depth plate girders supporting a skewed reinforced concrete slab. The unusual deck shape
resulted in the need for a complex system of height adjustable rollers and supports for the launch of
the new deck. The new bridge, 105m long with a launch weight of 2500 tonnes, was launched down a
variable slope using 4 No DL-S418 strand jacks, 2 No to pull the deck and 2 No to restrain the deck
from running away down the slope. Hydraulic jacks were used at all launch roller support positions to
continuously adjust the roller height and support load distribution throughout the launch. At the
intermediate pier position under the main span, between rail tracks, the deck was supported on a roller
system that was in turn supported on 8 No DL-C450 climbing jacks that were used to vary the roller
support level by 5 metres during the launch. Launching of the new deck was carried out in 21 No 3.5
hour overnight rail closures. All strand jacks and climbing jacks were controlled and synchronised by a
single operator using the DL-P40 computer control system.

DLT were responsible for all the conceptual and detailed construction engineering and temporary
works design, and for the supply and operation of all the jacking systems.
 Page 23

Project sheet - Tuti suspension bridge, Sudan

Khartoum, the capital of Sudan, is situated in a unique location surrounding the confluence of the
Blue Nile and White Nile. Tuti Island is located directly within this confluence, in a prime position in
the heart of the city. It is presently used principally as farm land, with some village housing, and has
been identified as an area with considerable development potential. There are no fixed links to the
island, access currently being by ferry. Tuti Bridge will provide the first road to it, as well as forming
a component of the strategic road network planned for the city.

The bridge will cross the Blue Nile at a point where it is around 200m wide. The river is fast flowing
with large seasonal variations in level, and construction within it can be hazardous. In keeping with
its location on a prime site in the centre of the city, the Sudan Government want the crossing to be a
signature bridge. Tuti Bridge will therefore be an elegant, modern suspension bridge with a main
span of 210 metres, which both provides the desired signature structure and avoids construction
within the river.
The suspension bridge deck is of steel/concrete composite construction, with a reinforced concrete
slab spanning longitudinally between transverse plate girders, which themselves span 16 metres
between longitudinal plate girders. The longitudinal members are attached to the two main
suspension cables, each of which comprises nineteen 70mm diameter galvanised steel spiral
strands. The substructure is reinforced concrete, supported on bored pile foundations which
penetrate into the underlying Nubian Formation. The large horizontal forces which are applied to the
suspension cable anchorages are resisted by vertical and raking piles, using a combination of axial
load and bending.
The principal challenge in the design of this bridge has been to provide an economical structure,
capable of being constructed using materials and methods suited to the Khartoum region. Particular
attention has therefore been given to developing simple structural solutions and components, using
where possible materials which can be easily obtained locally. In addition a construction method has
been developed which can be undertaken using locally available equipment and techniques.

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Page 24

Project sheet – CSC Blast Furnace No 2 relining, Taiwan

China Steel Corporation (CSC) have four blast furnaces on their main site in Kaohsiung, producing a
total of 24,000 tonnes of iron per day. Each furnace requires re-lining approximately every 10-15
years, involving the complete replacement of the furnace line. In 2005 CSC re-lined blast furnace No
2 with a new 12m diameter furnace line with an increased production capacity of 8,000 tonnes per
day. DLT were heavy lift sub-contractor and construction consultant to CSC for the installation of the
new furnace line weighing 3115 tonnes, which was delivered to the slag pit in eight segments
weighing up to 477 tonnes each. Each segment was delivered by self propelled modular trailers
onto two lifting beams in the slag pit, which were then lifted 14m up to skid track level using 8 No DL-
C125 climbing jacks. After lifting each segment was skidded 98m into the furnace house through a
temporary opening created in the side of the building, as shown below.

Once inside the furnace house each segment was lifted and aligned for welding using strand jacks
located on two levels. Eight DL-S185 strand jacks were used at the lower level and eight DL-S418
strand jacks at high level, all monitored and automatically synchronised using the recently developed
DL-P40 computer control system. Computer control was critical to the success of these operations,
to keep the loads evenly balanced between the ring of eight jacks at each level and to be able to
finely adjust the welding gaps between segments to between 1-3mm all around the joint.

All eight segments were lifted, skidded and aligned for welding in a period of 24 days, from lifting of
the first segment to final positioning of the last segment in the furnace house - requiring a total of 34
separate lifting and skidding operations. This was achieved through 24 hour working and close co-
ordination with the other sub-contractors. The total furnace shutdown period was 94 days.
 Page 25

Project sheet - Runyang suspension bridge, China

The deck erection gantries for the 1490m span Runyang suspension bridge were designed and
supplied by Dorman Long Technology to RBG. 2nd Highway Engineering Bureau, the main
contractor for the project. The main span of the steel bridge deck was been split unto 47 deck units,
each weighing up to 470 metric tonnes. These were fabricated offsite and transported by barge into
position under the main cables where they were erected using the deck erection gantries.

Erection of first deck unit Gantry during self erection onto the bridge cables
The gantries were designed in the UK to British standards. All mechanical components and the control system
were manufactured in Europe and shipped to site. The steel structure of the gantries was fabricated in China.
Once all components were on site the gantries were assembled, tested and erected within a period of 3
months. The fully assembled gantries, including deck lifting beams, were load tested to 125% of safe working
load and function tested on a specially design test frame.

The gantries are a new design, with many new features incorporated including:
• Designed for re-use on future bridges with varying cable centres and cable diameters
• Self erection and dismantling from the main cables at any point along the bridge.
• The gantries can also be erected and dismantled adjacent to the bridge pylons using tower cranes.
• Modular, lightweight construction for economic transport between sites. Fully operation, each gantry
weighed a total of only 130 tonnes including deck lifting beams
• All systems fully computer controlled for ease of use and for synchronisation of strand jacks during deck
lifting and gantry erection/dismantling.
• Fine adjustment of bridge deck level to within +/- 0.5mm
• Able to walk over cable bands of up to 1.9m long and 0.3m rise above the cable
• Able to incline the lifting strands through an angle of up to 15 degrees to the vertical to allow deck units to
lifted away from final plan position and swung across into final position
• All components weatherproof to IP65 and able to operate in temperatures down to minus10 deg. C

Each pair of gantries is capable of erecting deck units at a rate of one per day, but in practice the deck erection
programme was dictated by the delivery schedule of the deck units. The gantries were operated by local labour
under the supervision of Dorman Long. Erection of all 47 deck units took 12 ½ weeks, the last closure unit
being erected on 17th April 2004.

Gantry self erection sequence:

Step 1 Step 2 Step 3 Step 4 Step 5

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Page 26

Project sheet - Sutong Cable Stayed Bridge. Lowering of 3050 tonne steel caisson
to pier 4
The Sutong bridge across the Yangtze river near Shanghai has a main span of 1088m, which will make it
the longest cable stay bridge in the world when completed in 2007. Construction of the 118m x 52.3m x
18m thick pile cap to the main cable pylon P4 is currently underway by CHEC.2nd Navigation Engineering
Bureau, the main contractor for the north side foundations and approach spans. The reinforced concrete
pile cap is supported on 135 No. 2.85m diameter steel piles and has a 2m thick permanent steel caisson to
the sides which is designed to minimise damage to the pile cap during ship impact. This steel caisson also
acts as permanent formwork for casting of the pile cap concrete. The bottom 7m of the caisson was
assembled above water level on temporary support brackets welded to the piles, and then carefully
lowered into the water using strand jacks. DLT were heavy lift sub-contractors to CHEC for this lowering
operation, which took place on October 19th 2004.

The lowering operation was carried out using 16 No DL-S418 strand jacks, each jack having a safe working load of 418
tonnes, powered from 4 No DL-L114/4/D hydraulic power packs. The whole operation was controlled using the recently
developed DL-P40 computer control system, which uses a state of the art CAN network for ultra reliable
communication between jacks, power packs and the control computer. Accurate control of load distribution between the
jacks was essential for a safe lift and to achieve this the client specified a maximum differential movement between any
two jacking points of 10mm. The 3050 tonne, 7m deep, caisson was an unusually stiff load to handle as a relative
movement of 10mm between adjacent jacking points would cause a load redistribution of 35% of the jack load, a
situation which would quickly lead to a jack overload if not automatically detected and corrected by the DL-P40 control
system. Periodic level surveys and strain gauge readings were taken around the box by the client during the lowering
operation to check that we were achieving this requirement. The DL-P40 computer control system has intelligent nodes
at each jack that constantly monitor the jack stroke in relation to the max/min jack stroke advised to it by the DL-P40
control unit, and can instruct the power pack to adjust the oil flow to itself to maintain its position within the required
stroke range. In practice it was found that a stroke range of just 5mm was required to maintain a stable load balance
between the jacks.

Strand jacks were mounted on temporary cantilever frames, evenly spaced around the perimeter of the caisson, and
were connected to temporary jacking brackets welded to the inside wall of the caisson
 Page 27

Project sheet - Sheikh Khalifa Bin Salaman Causeway Bridge, Bahrain

The main span of the causeway is a double steel tied arch structure, spanning 121m and weighing
over 3000 tonnes. DLT were engaged by the steel fabricator/erector, Cleveland Bridge, to carry out
all erection engineering for this project. The main span was fully assembled in a yard some 300
miles from the site and then transported by barge into final plan position between the piers. The
complete deck was then lifted using 8 No 500 tonne strand jacks to final height and connected in the
air to pre-assembled end sections.

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Page 28

Project sheet - Tamar suspension bridge strengthening & widening, UK

The Tamar suspension bridge in the South West of England was constructed in the early 1960’s by
Cleveland Bridge & Engineering Company. It has a main span of 335m and two side spans of 114m
and was the longest bridge in the UK when it was opened in April 1962. In the late 1990’s Cleveland
Bridge were also awarded the contract to strengthen and widen the bridge. DLT were responsible
for value engineering of the permanent works and conceptual and detailed design of all erection and
demolition methods and related temporary works.
The bridge was widened from 3 lanes to 5 lanes by the addition of one lane cantilevers on either
side of the existing deck. Major strengthening and replacement works were carried out on the
suspended superstructure and approach spans. This included the addition of eighteen new stay
cables to the suspended spans, replacement of the original deck steelwork in the approach spans,
replacement of the concrete deck in the suspended spans and the erection of new deck cantilever
steelwork.

A major constraint on the construction process was the requirement to keep the bridge open to
traffic throughout the works, which raised complex engineering and safety issues. The upgraded
bridge was completed in 2001.

Before widening After widening

Deck cantilever erection gantries

 Page 29

Project sheet - Heathrow Airport Terminal 5, London

The new £3.5bn Terminal 5 at London’s Heathrow Airport is one of the biggest and most complex
building projects in recent times in the UK. DLT are responsible for conceptual and detailed design
of the erection systems for the 18,500 tonne steel roof of the main terminal building and for the new
1100 tonne steel air traffic control tower. Both structures are being fabricated off site and lifted into
final position using strand jacks.

The main terminal roof is being erected using methods more commonly found in major bridge
construction. The main roof comprises a series of tied arch steel box rafters with a clear span of
156m, supported on tubular leg assemblies. The leg assemblies are erected first, onto DLT specially
designed erection frames, followed by the box rafters. The rafters are assembled at ground level
and then lifted to full height in groups of four using strand jacks. Each lift is 2,000 tonnes and is lifted
with 16 No 185 tonne capacity strand jacks. The erection frames for the leg assemblies are
designed to provide fully adjustable support to each of the leg components and to and skid between
erection positions, avoiding the need to dismantle and re-erect.

The new aircraft control tower, shown below, comprises a control room mounted on steel mast, total
height 87.5m. The completed structure is stabilised using three pairs of pretension guy wires. The
need to keep all construction equipment beneath a radar ceiling together with a short construction
programme lead to the control tower being fully constructed in modules offsite and them assembled
on site using a computer controlled incremental jack up method, as shown below. The control room
and upper mast section was delivered first and jacked up progressively to allow 12m mast sections
to be attached to below. Temporary strand jack guys were used to stabilise the mast during lifting.
The tower was supported on an arrangement of hydraulic jacks during lifting, designed to allow
rotation and to provide damping to the system.

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Project sheet - Wembley National Football Stadium, London

When completed, the new £353m Wembley National Football Stadium will be the centre stage for
English football and the dominant building structure in North West London. Rising over the stadium
is a 1,490 tonne steel tubular lattice arch which is used to support the roof of the stadium. DLT are
responsible for the conceptual and detailed design of the erection systems, steelwork connections
and build pre-camber/pre-tension for all the 26,000 tonnes of steel used in the stadium, including the
stands, cable supported roof and arch structures. We are also responsible for strand jacking
operations carried out on the site, including the roll-up of the arch.
The arch has a span of 315m and a height of 133m. It was fabricated offsite in 21m long, 100 tonne
sections, and then brought to site for assembly at ground level. Once complete the whole arch was
rotated into final position using strand jacks, as shown below. The total weight of the arch, cables
and temporary works that were rotated from the assembly angle of 1.63 degrees through to the final
angle of 112 degrees was 2,831 tonnes. 20 No 418 te capacity strand jacks were used on the
pulling side and 5 No 580 tonne capacity strand jacks were used on the restraining side.

The detailed design of connections proved quite a challenge, many requiring finite element analysis
to verify our manual calculations. An example of one such complex node is shown below. This node
is in the roof and connects the roof cable members.
 Page 31

Project sheet - HAECO aircraft maintenance facility, Hong Kong

DLT were responsible for the design, supply & operation of a strand jack lifting system together with
all associated erection engineering to lift two 1000 tonne roof structures for the HAECO aircraft
maintenance facility at Hong Kong’s Chek Lap Kok airport. The roof sections were assembled at
ground level for speed and economy and then each was lifted to full height using nine 185 tonne
capacity strand jacks. Once lifted to full height the roof was connected along one side to a reinforced
concrete core and released from the jacking system.

Three 300 tonne capacity temporary jacking towers Lifting adjacent to the concrete core was carried out by
were used, each with two inverted strand jacks three inverted strand jacks housed in tension frames
climbing up static strands, as shown below. as shown below.

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Project sheet - Jacking tower system, 2500 tonne capacity, China

In 2002 we were engaged to carry out the conceptual and detailed design of a new modular jacking
tower system for the Chinese refinery construction market, to be owned and operated by No 4
Construction Company of Sinopec. The system uses strand jacks for vessel lifting and guying of the
tower and was designed with many new features, including:
• Low level assembly using mobile crane and self-erect/dismantle to full height of over 100m
• Tower luffing capability under full load
• Integral base skidding system
• Reduced sensitivity to ground settlement/rotation under load
• All components readily transportable by road between sites
The new system carried out its first lift in early 2003. It was used to erect a 92m long, 763 tonne vessel in a
chemical plant on the outskirts of Nanjing, China. (see below).

First lift Tower system during self-erection

Tower system operating sequence:

1. Tower self erected to full height 2. Vessel lifted using strand jacks 3. Vessel rotated and set down on
and vessel delivered over foundations
foundations

4. Tower skidded clear of 5. Tower self-dismantles to low 6. Tower ready for removal by light
vessel level mobile crane
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Project sheet - Gatwick Airport passenger bridge erection gantries, UK.

The new airport passenger bridge at Gatwick Airport, UK, is designed to take 3.5m passengers per
year over a busy aircraft taxi-way to the new Pier 6 satellite building. The fully enclosed footbridge
spans 128m across the taxi-way with a clearance height of 22m and is supported on two steel pylon
structures. The bridge was assembled off site and installed using strand jacks during a 10 day
closure of the taxi-way. DLT were responsible for the conceptual and detailed design of the
temporary erection gantries required to construct the bridge.

The bridge superstructure was fully assembled at ground level in a temporary construction area 1.5km from the
site. The central 175m long section weighed 2,185 tonnes, including the steel frame, composite floor, roofing
system, glazing and services. The two erection gantries were assembled around the bridge superstructure in
the temporary construction area and then load tested to 115% the maximum lift weight using the self weight of
the bridge and the temporary assembly foundations. The gantries were then used to lift the bridge
superstructure 1.5m to allow self propelled modular trailers (SPMT's) to be positioned under the bridge. The
bridge and gantries were then transported together across the airport to the final location on the SPMT's. The
gantries were then lowered onto prepared foundations ready for lifting the bridge. Eight 418 tonne capacity
strand jacks mounted at the top of the two gantries were then used to lift the bridge to approximately 2.4m
above final level to allow installation of the pylons beneath. The two pylons were hung from the underside of the
bridge and the complete assembly, weighing 2,660 tonnes was then lowered by the strand jacks onto the
permanent foundations. The gantries were then dismantled and removed from site.

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Project sheet - Formosa Plastics Plant, Taiwan

The new Formosa Plastics petrochemical plant in Mai-Liao, Taiwan, is one of the biggest refineries
& chemical plants in the world. All the large vessels, weighing up to 1450 tonnes, were erected
using a modular jacking tower system designed and supplied by Dorman Long Technology. We also
provided site supervisors to oversee the majority of vessel lifts and carried out vessel specific
erection engineering. The jacking tower system uses up to 4 No 580 tonne capacity strand jacks for
lifting and 4 No 105 tonne capacity strand jacks for guying and can be used in a number of
configurations as shown below. The system is capable of being used without guys for the reaction of
vessels up to 35 m tall and 1100 tonnes.

Erection of 77m high, 760 tonne column Erection of multiple 30m high, 1100 tonne reactors using unguyed
jacking tower that is skidded between vessel erection positions

Erection of 132m high, 1350 tonne column using jacking tower in ‘U-frame’ configuration in which
the vessel rises above the top of the tower and passes through a U frame at the top of the towers.

Erection of a 780 tonne

regenerator into the
permanent support
frame, with the jacking
tower system mounted
on the top of the frame
 Page 35

Project sheet - Tsing Ma suspension bridge, Hong Kong

With a main span of 1377 m, the Tsing Ma suspension bridge in Hong Kong is the fifth longest
bridge in the world. Working for the main contractor, Anglo-Japanese Construction JV, we were
responsible for erection engineering for all elements of the deck, main cables (spun) & hangers
together with supply and operation of heavy lifting equipment. Our work included full geometric and
stability calculations for the superstructure at all stages of construction. The steel deck was erected
in pre-assembled units weighing up to 1000 tonnes by gantries mounted on the cables as shown
below. Pre-assembled side span steel deck units weighing up to 1450 tonnes were assembled at
ground level adjacent to the piers and then lifted vertically and skidded horizontally into final position
as shown below. All deck lifting and skidding operations were carried out using strand jacks supplied
by DLT.

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Page 36

Contacts
UK Midlands Office – Head Office:
The Charles Parker Building, Midland Road,
Higham Ferrers, Northamptonshire, NN10 8DN, United Kingdom
Tel. +44 (0)1933 319133, Fax. +44 (0)1933 319135
Contact: David Dyer. david.dyer@dormanlong.com
Mike Wade. mike.wade@dormanlong.com

UK Northern Office:
Whessoe Technology Centre
Morton Palms, Darlington
Co Durham, DL1 4WB, United Kingdom
Tel. +44 (0)1325 390010, Fax. +44 (0)1325 390054
Contact: Chris Wilkinson. chris.wilkinson@dormanlong.com

UK Southern Office:
Leatherhead, Surrey, United Kingdom
Tel. +44 (0)1372 860 800, Fax. +44 (0) 01372 860 801
Contact: Peter Whatling. peter.whatling@dormanlong.com

China representative office:

Office 1658, World Trade Centre, Xinjiekou Street
Nanjing, 21005, People's Republic of China
Tel. +86 (0)1395 1758372
Contact: Hongyi Tao. hongyi.tao@dormanlong.com

China Office:
Dorman Long Engineering Technology Consultant (Shanghai) Co. Ltd
10B, Ju Jia Building
1336 Huashan Road
Changning District, Shanghai 200052
Tel. +86 (0) 21 62110500/62110520, Fax: +86 (0) 21 62110523
Contact: Hongyi Tao. hongyi.tao@dormanlong.com

Russia & CIS representative office:

PROMTECHSERVICE Co Ltd.
117519, Moscow, Russia, Varshavskoe shosse 138
Tel.: +7 (495) 788-5482, +7 (495) 765-2936
Fax: +7 (495) 788-5483, +7(495) 936-2005
Contact: Sergey Mekhedof. info@promts.ru

India Representative Office:

233, Bharat Industrial Estate
L.B. Shastri Marg, Bhandup (W)
Mumbai - 400 078, India
Tel. +91 222 5961960
Contact: Rajeev Tipnis. rajeev.t@vsnl.com

South America representative office:

Locar Transportes Tecnicos e Guindastes Ltda
Rua João Pedro Blumenthal, 200 - Cumbica
CEP 07224-150 - Guarulhos - Sao Paulo - Brasil
Tel. +55 (11) 6413.6600, Fax. +55 (11) 6413.6622
Contact: Camilo José S. Filho. camilofilho@locar.com.br

West Africa representative office:

Boltog Limited
Boltog House, No 94B Old Aba Road, Rumuobiakani
Port Harcourt, Nigeria
Tel/Fax. +234 (84)487564
Contact: Ndy Nkpa. n.nkpa@qis-boltog.com

Middle East representative office:

P.O Box 16765, Dubai, UAE
Tel. +971 4 883 5551, Fax. +971 4 883 7528
Contact: Michael Mack. mack@clevelandbridge.co.ae