SYDNEY METRO BARANGAROO

SYDNEY METRO BARANGAROO

A world record tower crane lift for Sydney Metro

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PROJECT OVERVIEW

Located 25 metres below ground level on the southern shore of Sydney Harbour, construction of the new Barangaroo Station included extensive tunnelling and excavation works – and a lot of heavy lifting in a seriously congested area. Construction partners, John Holland CPB Ghella (JHCPBG) joint venture, engaged Marr during the tender process to develop a craneage solution that would allow them to install heavy pre-cast elements and reduce the construction programme.

Client
JOHN HOLLAND CPB GHELLA (JHCPBG) JOINT VENTURE
Project
SYDNEY METRO BARANGAROO
Location
BARANGAROO STATION SITE
Sector
LARGE-SCALE CONSTRUCTION
Date
2018 – 2021
Cranes

1 x M1280D

1 x M2480D

THE CHALLENGE

A heavy lift solution for the excavation and construction works – including the removal of TBM sections weighing up to 255 tonnes – within a congested site with limited access and real estate for the movement of equipment around the site.

OUR SOLUTION

By installing a M2480D and M1280D on purpose-designed foundations in and outside of the station box our solution provided lifting capacity across the entire project – taking up 90% less room than the originally proposed traditional crawler crane and gantry set up.

THE RESULT

Using our higher capacity cranes gave JHCPBG the option to build with precast beams allowing for increased modularisation and fewer lifts which in turn reduced congestion, improved site utilisation, and reduced complexity, risk and time on the project.

THE LOCATION
Located on the southern shore of Sydney Harbour at the western edge of the CBD, the new Sydney Metro Barangaroo Station will connect the Sydney Metro line between the city and northern suburbs via a kilometre-long twin tunnels under Sydney Harbour.
EARLY PROJECT ENGAGEMENT

Construction partners, John Holland CPB Ghella (JHCPBG) joint venture, engaged Marr during the tender process to develop a craneage solution that would support the extensive tunnelling and excavation works required and their proposed construction methodology – which included the installation of heavy precast elements – for the new underground station and large crossover cavern.

THE CHALLENGE

Flanked by the Harbour, a rockface and another development to the south, the already congested site posed significant access and mobility issues for JHCPBG. The originally proposed craneage scheme was to use multiple mobile cranes and a 600-tonne capacity crawler but this was inefficient in such a congested space.

OUR SOLUTION

Marr’s solution was to install one of our M2480D and M1280Ds sitting alongside the station boxes to provide lifting capacity across the project. Set on purpose-designed foundations in and outside of the station box, the cranes took up 90 per cent less room than the proposed traditional crawler crane and gantry set up

A WORLD RECORD LIFT
In addition to the excavation, tunneling and general construction works, JHCPBG’s scope of works also included launching and retrieving the cutter heads and shields of two tunnel boring machines (TBMs). With our M2480D installed inside the station box at the exit point of the tunnel and configured with a 55-metre boom and six fall 330-tonne hook block, we were able to remove the 255-tonne TBM sections in a single lift. It was the first time a tower crane had been used to lift a TBM component of this weight – and set a world record for the heaviest lift by a tower crane.

After the TBM was dismantled and transported offsite, the M2480D was reconfigured to continue general construction works on the project. Using Marr’s higher capacity cranes gave JHCPBG the option to build with precast beams allowing for increased modularization and fewer lifts. Marr’s approach has also reduced congestion, improved site utilization, and reduced complexity, risk and time on the project.

“The M2480D heavy lift tower crane was the only solution for the job. With a very limited footprint and heavy loads to lift, the M2480D saved time on the program by minimising the number of crane lifts required, without impacting construction activities of the Barangaroo Station works adjacent,” said Dan Caldicott, JHCPBH Barangaroo Station Site Superintendent

LET'S TALK ABOUT HOW WE COULD ADD VALUE TO YOUR PROJECT

We work with our clients to find a craneage solution that works – no matter how big or complex the job is. If the right crane doesn’t already exist, we’ll build one to suit the needs of your project.

ABOUT US

We’re not just a crew and cranes for hire. We’re big thinkers and problem solvers who love a challenge. No problem is too big for us.

OUR PHILOSOPHY

We believe that the crane needs to suit the job, not the other way around. We don’t just hire cranes – we design craneage solutions.

OUR HERITAGE

We’re a third-generation family-owned and run business with a strong sense of tradition and loyalty engrained in what we do and how we work together.

OUR PEOPLE

We think of our team as ‘one big family’ of problem-solvers who love cranes and the challenge of working on complex, large-scale projects.

OUR APPROACH

We work with you to find an engineering solution that works. Delivering value through the unique combination of our knowledge, experience, proven service delivery and people.

OUR SERVICES

We’ve worked on some of the most complex and challenging large-scale construction projects across Australia and around the world.

OUR CRANES

We don’t just hire cranes – we design them. So, if the right crane for your job doesn’t already exist, we’ll build one.

OUR PROJECTS

With almost 100 years’ experience, we have a reputation for taking on projects that others can’t or won’t.

SAFETY, QUALITY & ENVIRONMENT

We take on the jobs that many others can’t or won’t – but we always put good business practices first.

SUSTAINABILITY

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SOCIAL IMPACT

As problem-solvers who love a challenge, we are never shy of tackling the big issues.

DIVERSITY

We are committed to creating a diverse, inclusive and flexible workplace that reflects the clients and communities we work with.