Dual Silo Lift in Broomehill Village, WA

Two Cranes, One Chance: Lessons from a Dual Silo Lift in Broomehill Village, WA

When lifting a tall, top-heavy structure like a silo, there’s no margin for error—especially in regional settings where ground conditions, wind exposure, and limited support infrastructure pose unique challenges.

In Broomehill Village (WA 6318), our team completed a critical dual-lift operation to install a vertical steel silo, safely positioning it onto its foundation using a 160t and a 250t mobile crane in tandem.

This post outlines the key takeaways and engineering decisions that made the lift a success, in full compliance with Australian standards.

Project Snapshot

  • Location: Broomehill Village, Western Australia

  • Structure: Steel grain silo (preassembled vertical unit)

  • Weight: 46 tonnes

  • Cranes Used:

    • 160t (bottom end, 12m radius, 37m boom)

    • 250t (top end, 8m radius, 31.1m boom)

  • Method: Dual-lift with spreader bar and tailing strategy

  • Final Placement: Silo stood upright by 250t crane after tailing

Key Lessons from the Dual Silo Lift

1. Ground Preparation Is Everything in Rural Sites

Grain silo foundations are typically remote and built on compacted earth or gravel—not engineered slabs.

  • Lesson: Pre-lift site assessments must include ground-bearing verification for crane outriggers. We used compaction test data to verify each crane pad could withstand the load.

2. Dual-Lift Sequencing Must Account for Load Swing

Unlike rigid towers, silos tend to shift center of gravity mid-lift—especially if there’s slight asymmetry or if internal bracing flexes.

  • Lesson: Both crane operators must be in synced communication, and the lift plan should include staged increments with visual cues and taglines to manage swing.

3. Wind Load on Curved Surfaces Is Amplified

A silo’s round, vertical shape turns it into a sail under moderate wind. Even at 5–6 m/s, the structure can twist or sway in unexpected ways.

  • Lesson: We monitored real-time wind data and paused the lift at 6.5 m/s, following AS 2550 crane operations wind thresholds.

4. Spreaders Aren’t Just for Lifting—They Prevent Structural Collapse

Using a certified spreader bar allowed even distribution across lifting lugs welded to the silo.

  • Lesson: Without this, localized stress could’ve led to deformation, especially around thin-wall sections at the top rim.

5. Tailing the Load Requires Precision Timing

The 160t crane was used to tail the base of the silo during the lift. If the lead crane (250t) outpaces the tail crane by even 200mm, the entire lift angle becomes unstable.

  • Lesson: We used laser rangefinders and spotter feedback to sync hoisting speeds and maintain center alignment.

6. Remote Locations Need Redundant Risk Controls

In isolated towns like Broomehill, backup gear and personnel aren’t a phone call away.

  • Lesson: Our planning included on-site spares for rigging gear, backup radios, and pre-checked evacuation routes for any unexpected incident.

Conclusion: Regional Doesn’t Mean Risky

This Broomehill silo lift demonstrates that with smart engineering, precise crane coordination, and adherence to Australian standards (AS 1418, AS 2550), even remote projects can be executed to the highest level of safety and reliability.

Whether it’s a tower or a silo, the lesson is the same: success isn’t in the steel—it’s in the study.

Optus Telco Tower Lift - Ballidu WA 6606

The Hidden Risk in Telco Tower Lifts Most Crews Miss – And How We Planned Around It

1. Fall-Arrest Loads Must Be Engineered into the Lift Plan—Not Just the Structure

  • Most tower designs comply with AS/NZS 1891.3, which defines fall-arrest loads (~20.3kN for 4 persons).

  • But if you lift a tower pre-rigged with fall-arrest hardware, that load rating must be verified during lift planning—especially if the tower is entered while suspended or immediately post-lift.

  • Lesson: Treat the fall-arrest system as a live structural load, not a passive feature.

2. Lift Radius Dictates Safety Margins—Not Just Load Charts

  • A common mistake is to treat the crane’s lift capacity as fixed.

  • In reality, even a slight increase in boom length or radius (e.g., from 8m to 9.5m) can dramatically reduce capacity and safety margin—especially for dual lifts or long towers.

  • Lesson: Always simulate worst-case radius drift due to rigging swing, wind sway, or operator offset.

3. Ground Pressure Checks Are Critical When the Tower is Tall and the Access is Tight

  • Telco tower sites often involve confined rear access or soft ground.

  • Even a correctly rated crane can cause failure if outrigger loads exceed ground-bearing capacity.

  • Lesson: Use lift planning software or geotech input to confirm outrigger load zones—especially near trenches or underground services.

4. Wind Is the Silent Saboteur of Tall, Light Structures

  • TECO towers are tall and slender, making them susceptible to wind drift, especially when lifted fully assembled.

  • Australian Standards require lifts to stop if wind exceeds certain thresholds (typically 7–10 m/s for non-enclosed loads).

  • Lesson: Incorporate wind monitoring, define stop triggers, and consider temporary bracing/taglines during lift.

5. Australian Standards Define the Baseline—But Your Risk Appetite Defines the Real Plan

  • Compliance with AS/NZS 1418 (Cranes), AS/NZS 1891 (Fall-Arrest), and AS 2550 ensures legal coverage.

  • But real safety comes from planning for site-specific risks: unknown underground services, fatigued crew, poor visibility, conflicting subcontractors, etc.

  • Lesson: Use the standards as a floor, not a ceiling. Your planning process should go further.

6. Communication Protocols Save Lives When Lifting Vertical Structures

  • When visibility is obstructed (e.g., rear of building, nighttime work), even experienced crews can miscommunicate.

  • Having clear stop signals, dual-channel radios, and pre-lift briefings for every crew member is essential.

  • Lesson: Assume miscommunication will happen—and design around it with repeatable SOPs.

When it comes to erecting a TECO tower, especially on constrained or live sites, there is no room for improvisation. Every meter of elevation brings not just height, but risk. At Midland’s latest installation, our team executed the lift of a prefabricated TECO tower using a mobile crane under tight spatial and environmental conditions.

The lift involved:

  • Erecting a TECO tower designed to accommodate a 4-person fall-arrest system.

  • Utilizing a single mobile crane, strategically placed to ensure optimal reach and minimal ground impact.

  • Fall-arrest equipment installed in accordance with AS/NZS 1891.3 and manufacturer specifications .

Challenges Faced

  1. Confined Access

    The rear access via Lloyd Street allowed limited setup area for the mobile crane. Every outrigger placement had to be millimetre-perfect to avoid underground services and unstable terrain.

  2. Tower Stability During Lift

    The tower’s height and surface area made it susceptible to wind sway. The team conducted wind speed monitoring and used taglines to stabilize the lift during positioning.

  3. Safety at Height

    With workers expected to access the tower during final alignment and bolting, the structure’s integrated fall-arrest anchor points needed to comply with Australian standards and be operational immediately upon erection.

Risk Mitigation Through Planning

  • Lift study modeling simulated crane setup, boom angle, load radius, and clearance to overhead hazards.

  • Engineering review confirmed that the crane’s ground pressure and setup were compliant with site limits.

  • Communication protocols were established between riggers, crane operator, and spotters with predefined stop signals.

  • AS/NZS compliance was ensured across rigging hardware, personnel protection systems, and lifting sequences.

Conclusion

What could be a risky vertical installation became a smooth and safe lift thanks to detailed planning and execution. In today’s high-stakes construction environment, risk isn’t eliminated on the day—it’s designed out weeks before the crane even arrives.

If you’re planning a complex lift like this, make safety and certainty your first load—get a tailored lift study that aligns with Australian standards and site constraints.

Dual Crane Lift at Midland TAFE

At Midland TAFE, a highly coordinated dual-lift operation was recently executed involving a heavy vertical cylindrical component. The lift was accessed via the rear of the TAFE off Lloyd Street, with clear access ensured (note: the large excavation seen in some site photos will not be present at the time of the actual lift).

Two mobile cranes were used for this operation:

  • A 160t crane (working at a 12m radius with full counterweight and a boom length of 37m) was rigged at the base end of the load.

  • A 250t crane (working at an 8m radius, also with full counterweight and a 31.1m boom) handled the top end.

The cylindrical structure, weighing 46 tonnes, was lifted directly off transport using a spreader bar at the top and tailed at the base. The lift was carefully synchronized to maintain control throughout the vertical transition, with the 250t crane ultimately placing the load into its final position.

This type of dual lift requires meticulous planning, including precise boom angles, rigging design, and lift sequencing. The visual you see above illustrates the full setup.

For more technical details or a formal lift study, feel free to reach out.