Bridge Beam Lift at Taylors Road Bridge Bonnie Brook VIC 3336

Bridging the Risk: How a 450t and 250t Crane Duo Delivered Precision at Taylors Road Bridge

Bonnie Brook, VIC – Dual-Lift Execution on Live Infrastructure

Installing bridge beams is always high-risk—but doing it over active infrastructure in a developing growth corridor like Bonnie Brook raises the stakes. At Taylors Road Bridge, our team executed a flawless dual crane lift of precast bridge beams using a 450-tonne and 250-tonne mobile crane.

This case study outlines the engineering, planning, and key lessons from the lift—providing practical insights for contractors, developers, and civil engineers working under tight tolerances and live road constraints.

Project Snapshot

  • Location: Taylors Road Bridge, Bonnie Brook, VIC

  • Scope: Dual lift of precast bridge beams

  • Beams: Up to 40t each, ~30m long

  • Cranes Used:

    • 450t (primary lift)

    • 250t (tailing and positioning support)

  • Conditions: Limited night possession window, restricted outrigger setup, high-traffic corridor

Key Lessons from the Lift

1. Beam Stability Depends on Synchronized Boom Angles

In a dual-lift scenario, any imbalance in crane movement can twist or deflect the beam mid-air.

  • Lesson: A live digital boom-angle readout and synchronized hoisting speeds were critical to maintaining beam level during rotation and lowering.

2. Urban Bridge Sites Require Millimetre-Accurate Setup

With services, traffic lanes, and barriers to avoid, crane pads had to be positioned precisely.

  • Lesson: We used total station equipment to mark out outrigger pads within ±20mm tolerance, pre-poured with steel-reinforced mats to distribute loads.

3. Lift Timing Was Dictated by Possession Windows, Not Preferences

The job had to be executed overnight during a rail corridor shutdown.

  • Lesson: Every delay had cascading impacts. We built in time buffers between rigging, lift, and set-down operations—and pre-staged backup rigging gear onsite.

4. Wind Control Is Non-Negotiable with Long Span Beams

Even slight gusts can sway a 30m beam.

  • Lesson: We used wind socks and anemometers at both crane tips and halted the lift at 7.5 m/s per AS 2550 guidance.

5. The 450t Crane Did the Heavy Lifting, But the 250t Made It Precise

While the 450t crane bore the bulk of the load, the 250t crane at the beam’s tail allowed for fine-tuned control to lower the beam into tight abutments.

  • Lesson: Dual-lift strategy isn’t just about load capacity—it’s about placement accuracy.

6. AS Standards Set the Bar—But Local Council Requirements Went Further

Complying with AS 1418 and AS 2550 was necessary, but not sufficient. The local council required additional reporting: lift studies, engineer signoff, environmental controls, and impact assessments.

  • Lesson: On public infrastructure, compliance means aligning with both codes and stakeholders.

Conclusion: It’s More Than a Lift—It’s Public Infrastructure in Motion

At Taylors Road Bridge, we didn’t just lift beams—we delivered trust, certainty, and schedule adherence. With a 450t and 250t crane working in harmony, and a plan built around Australian standards and local approvals, we turned complexity into confidence.

If your next bridge project needs critical-path lifting, reach out for a compliant, engineered lift plan that won’t let you down when time matters most.