Time is of the essence on any lifting project, but it should never be the driving force at the expense of safety. The ability to find a balance between these two factors, combined with creative problem solving skills, has placed Johnson Crane Hire at the forefront of lifting service provision. The company continues to deploy its engineering expertise and technology to ensure efficient and safety driven solutions. In an example of its innovative attitude, Johnson Crane Hire successfully completed a specialised lifting solution at the B2Gold Otjikoto Project in Namibia, using an alternative lifting methodology.

This was made possible through Johnson Crane Hire’s extensive track record in undertaking challenging lifts, coupled with the 13 years of experience that engineer James Robinson brings to the table in alternative lifting technology. Robinson, who is the heavy lift manager for crawler cranes and projects at Johnson Crane Hire, says that the company’s solid track record is based on designing and engineering heavy lifts that are customised to specific customer requirements and are centred on irrefutable safety adherence.

The B2Gold Otjikoto gold project, which is located 300 kilometres north of Windhoek, will rank as the country’s second and biggest gold mine when it enters production before the end of 2014. The current mine plan is based on probable mineral reserves of 29.4 million tonnes to be mined over an initial 12-year period. Schedules to timeously complete the mine infrastructure and plant are tight and required a lifting solution that would provide both time and cost savings.

Robinson explains that Johnson Crane Hire’s ability to understand its customer’s specific requirements enables the company to offer the most appropriate lifting solution. “One needs to have an understanding of the nature of the lift, the risks involved and any limitations. The planning process is critical to the success of a heavy lift and begins with an initial site inspection which is followed by a more intensive on-site visit by Johnson Crane Hire’s technical heavy lift team. In this way, the team is able to verify measurements and dimensions which are then passed on to the engineering team who undertake a 2D or 3D CAD rigging study.”

The scope of the Otjikoto project involved the lifting, moving and positioning of CAT gensets from the outside of the building into position inside the building. The gensets were manufactured overseas and shipped to the Port of Walvis Bay, then transported via road to Otjikoto.

Over a period of eight days Johnson Crane Hire offloaded the genset components from the low bed trucks onto the company’s recently acquired jacking and sliding system, using a 200-ton mobile crane. This new system is unique, as it is ultra-portable, allowing optimum flexibility in terms of where this sort of lift can be undertaken. “This is especially important at remote sites like Otjikoto, where access to technology is limited by logistics,” Robinson adds.

Each of the gensets comprises three major components – the base frame, engine and alternator. Once Johnson Crane Hire had offloaded these components, they were assembled by the company, in collaboration with a representative from the OEM. Each genset, with a mass of 120 t, was slid into position along a Teflon rail system, and together with a plumb line, Johnson Crane Hire was able to laterally and longitudinally place the gensets to an accuracy of within one millimetre of the final positions.

“One of the biggest advantages of the portable jacking and sliding system is that it is easy to set up and does not need additional equipment to reposition it. The only requirement is the necessary technology experience and knowledge. With the requisite training, our team was able to quickly and seamlessly erect the system for maximised time optimisation,” says Robinson.

Underlining everything that Johnson Crane Hire does is a focus on safe lifting techniques. This has stood the company in good stead for the past 35 years and forms a critical cornerstone in the SMART (Safety, Maintenance, Availability, Reliability and Total cost effectiveness) business credo.

All lifting equipment is kept in optimum condition through regular, proactive maintenance schedules and on-going inspections. In addition, the company invests in its highly skilled and trained operators to ensure that they are also completely familiarised with the application of comprehensively documented and implemented safety systems.

“We are intent on exceeding local industry safety standards and we perform comprehensive risk assessments before each lift. Training is provided both externally and at the Johnson Crane Hire training centre to ensure that our operators are up to date on the latest technology,” Robinson points out.

“The successful completion of the specialised lift at B2Gold Otjikoto is testament to Johnson Crane Hire’s market driven competencies and clearly demonstrates that speed and safety are not necessarily exclusive of each other when the correct team and technology is applied,” he concludes.