Successful Commissioning of 200-Ton Bridge Launching Gantry in Indonesia

Project Overview

This case study involves a highway junction bridge project in Sumatra, Indonesia. The site features complex geology and spans dominated by 30m and 40m prestressed concrete box girders. To install 180 box girders within a strict schedule, we provided a customized bridge launching gantry, including full on-site assembly, commissioning, and operator training.

Bridge Launching Gantry Parameters

Designed for challenging conditions, this equipment features a modular structure with a high-stability control system:

• Rated Capacity: 200 tons
• Applicable Span: 30m – 40m
• Rated Lifting Height: 12m
• Main Structure: Truss main girder, dual-trolley synchronization system
• Control System: Industrial PLC with auto-correction and real-time load monitoring
• Operation: Longitudinal travel, cross-travel, span-passing, and continuous girder installation

Bridge Launching Gantry Installation Implementation

The site at the bridge approach was narrow with limited roadbed capacity, requiring structural reinforcement. Installation proceeded in three key phases:

• Phase 1: Structural Assembly & Load Distribution: Due to narrow mountainous terrain, the main girder was transported in sections and joined via high-strength bolts. We configured sleeper and steel plate foundations based on site ground parameters to ensure ground pressure met safety requirements.
• Phase 2: Hydraulic System Commissioning: Focused on hydraulic legs and longitudinal travel. We performed 10 reciprocating tests on cylinder strokes, pressure balance valves, and synchronization systems. Adjusting proportional flow valves ensured lateral stability during pier transitions.
• Phase 3: Static Load Test & Acceptance: Per ISO/FEM standards, we applied a 110% load (220 tons) to the mid-span for 20 minutes. Monitoring confirmed deflection was within norms, with no abnormal vibration/leaks and accurate control logic.

Operational Results

Post-delivery, the installation cycle for a single 90-ton box girder was consistently under 180 minutes. During three months of initial operation, the equipment withstood high humidity and seasonal winds. Real-time PLC load data and remote diagnostics helped the site team avoid operational risks, achieving “zero-accident” status.

This project proves that HSCRANE bridge launching gantries provide reliable hydraulic control and efficient modular assembly, significantly reducing maintenance costs in complex overseas environments.

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.

[email protected] WhatsApp LinkedIn

Share this article