150t Bridge Launching Gantry Export to Indonesia: HSCRANE Bridge Construction Case Study

Project Background

The Sumatra Toll Road in Indonesia is a key infrastructure project in the region. Section 3 of this project is located at the edge of a tropical rainforest, featuring rugged terrain and a long rainy season. The route includes multiple precast T-beam bridges spanning rivers and deep valleys. This puts strict demands on the lifting capacity, mobility, and environmental adaptability of construction equipment. The general contractor compared solutions from several international crane brands. Due to complex geological conditions, standard models struggled to pass holes and feed beams safely within the limited pier-top working space. After analyzing the site survey data, the HSCRANE technical team customized a 150t bridge launching gantry solution. We ultimately won the client’s trust through our precise technical design and fast delivery.

Core Parameters & Targeted Improvements of the 150t Bridge Launching Gantry

To meet the special needs of this project, the 150-ton bridge launching gantry was upgraded from our standard model. Its core technical parameters include:

• Rated Lifting Capacity: 150 t
• Adaptive Bridge Span: 40 m (supports 30m, 35m, and 40m T-beam installation)
• Maximum Working Longitudinal Slope: 4%
• Maximum Working Cross Slope: 3%
• Minimum Curve Radius: 550 m
• Total Installed Power: 132 kW
• Main Girder Structure: Assembled triangular truss double guide beams
• Control System: Variable frequency speed control + wireless remote control + cabin dual backup system

Because the local climate features year-round high temperatures, high humidity, and frequent thunderstorms, engineers upgraded the electrical systems to IP55 protection. They also added independent industrial dehumidifiers and cooling fans inside the PLC control cabinets. To handle frequent heavy rain, workers performed high-standard sandblasting on all structural parts to remove rust. Then, technicians applied an epoxy zinc-rich anti-corrosion primer and a polyurethane topcoat with a total thickness of at least 240μm, ensuring the equipment resists rust on harsh overseas sites.

Logistics Challenges: Ocean Freight & Mountain Transportation

Delivering a large bridge launching gantry overseas makes logistics the first major hurdle. HSCRANE dismantled this massive machine into modular truss sections, front support legs, rear support legs, trolleys, and hydraulic pump stations. The entire machine required four 40-foot high cube containers (HQ) and two flat rack containers (FR) for ocean shipping.

After the equipment arrived at the Indonesian port, a fleet transported it 120 kilometers over mountain roads. Since the roads along the route were narrow and rough, the advantages of the modular design became clear. The design kept the longest and heaviest components within local road transport limits. HSCRANE sent two experienced field installation engineers along with the shipment. They began assembly preparation the very day the equipment arrived at the construction site.

On-Site Assembly, Rigorous Commissioning, and First Span Hole Crossing

On Indonesia’s red soil, heavy rains often poured down without warning. Lacking large cranes for assistance, HSCRANE engineers guided local workers during the gantry assembly. The team used a truck crane and two chain hoists on the prepared bridgehead roadbed, building the machine like blocks.

After 10 days of intense work, the bridge launching gantry was fully assembled. Before official beam placement, strict third-party certification tests were conducted on-site:

1. No-load Test Run: Checking hydraulic lifting actions of the front, middle, and rear support legs, and testing longitudinal and transverse travel limits of the trolley.
2. Static Load Test (1.25x): Using precast concrete blocks to apply a 187.5-ton static load to the main girder. Elastic deformation was measured, and the results perfectly met national standards and design requirements.
3. Dynamic Load Crossing Test (1.1x): Simulating extreme travel conditions under a 165-ton load to verify the overall anti-overturning stability factor.

Installing the first 40-meter, 138-ton precast T-beam marked the critical milestone of the project. In the morning, a beam carrier slowly fed the T-beam into the rear of the bridge launching gantry. A hydraulic synchronization system precisely controlled the feeding, lifting, longitudinal moving, transverse moving, and positioning. Adjusted by the VFD, the trolley showed excellent micro-positioning performance, keeping the beam-lowering error within 2mm. When the first beam rested firmly on the rubber bearings, the local Indonesian owners and general contractor burst into applause.

Delivery Value and Client Feedback

With the equipment running smoothly, the beam installation speed jumped from the planned 2 spans every 3 days to 1 span per day. This slashed the waiting time for subsequent road paving. Throughout the construction cycle, this HSCRANE 150t bridge launching gantry suffered zero downtime from mechanical or electrical failures. Its high stability and safety won unanimous praise from the project department.

The success of this project laid a solid foundation for opening the highway to traffic. It also proved HSCRANE’s rapid customization ability for complex overseas conditions in non-standard heavy lifting equipment. By providing integrated “product + overseas technical support” services, heavy equipment made in China is taking deeper root in global infrastructure development.

Mark Meng

Bridge Construction Equipment Specialist

Bridge construction equipment specialist with focus on launching gantry structural design, hydraulic synchronization systems, and on-site erection methodology. Experienced in technical requirement analysis for span-by-span and full-span launching projects across varying terrains and load capacities.

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