Andre Construction was contracted to supply and install a new crane rail along the dam headworks of a power generating station. The work was required as part of life-extending refurbishments across the site.
The project involved the removal and replacement of the existing grout bed and crane rail, installation of new crane rail plates and grounding systems, and waterproofing of the new grout along the rail.
As lead contractor, Andre Construction was responsible for the removal and replacement of the grout bed. The team oversaw subcontractors handling a rail alignment survey, removal and replacement of the rail, and grounding installation.
A significant amount of rebar was discovered at the rail plate drilling sites, making it impossible to set the plates properly.
A re-design of the crane rail plates was required to allow drilling in locations where there was no rebar, impacting the project timeline and budget.
Headworks material removal required use of the crane during the project, which slowed work on the crane rail.
The new crane rail grout required waterproofing measures beyond the original scope.
Work was ongoing during the COVID-19 pandemic. Heightened restrictions and requirements for protection limited onsite resources and slowed completion of work.
To accommodate the rebar in the headworks, Andre Construction redesigned the crane rail plates with oversized slotted holes. This allowed for additional drilling locations in areas without rebar and ensured proper setting of the rail plates.
While material removal prevented work on the crane rail, the team continued with less critical tasks on unoccupied sections of the dam to keep the project moving forward.
When the new crane rail grout dried with hairline cracks, the team added a waterproof membrane to protect the grout from water damage.
To reduce delays related to increased COVID-19 protection requirements, Andre Construction implemented new guidelines and protocols to keep employees safe and able to work. With updated protocols the team maintained a consistent schedule and adhered to project timelines.
The new crane rail system was successfully installed and commissioned in June 2020. The new system ensures smooth movement of the crane across the entire dam.
The project was completed without any safety incidents and met all quality and workmanship expectations.
This project highlighted the importance of having accurate drawings prior to starting drilling or design work. Because the original drawings weren’t representative of real-life conditions, concrete scanning and an eventual plate redesign were required to successfully complete the project. Ensuring accuracy at the outset reduces costs and downstream delays.
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