Barnhart was tasked with lifting large mechanical, electrical and plumbing (MEP) modules at a Texas manufacturing site’s utilities building. The modules needed to be attached to the building's ceiling and lifted over 25 feet for installation. The initial solution required the contractor to make hundreds of welded connections of up to 64'' large-diameter pipes at elevation. This would extend the schedule, require more manpower working at height, increase congestion and impact safety risk.
Barnhart’s engineers and fabrication shop worked with the contractor to devise a safer solution, which involved creating two new tools: Lift Tables and Jack Masters. These portable tools could be trucked in and set up at the site using machinery moving skates and a motorized pallet jack. The contractor’s crews connected longer and larger areas of pipe and steel at grade before Barnhart lifted the modules. This approach increased safety and efficiency by allowing work to be done at ground level instead of at height.
The Jack Masters lifted the modules, weighing up to 300,000 pounds, to a height where the LT50 Lift Tables could be positioned to take over. They then lifted the units from 40'' off grade to approximately 26' in one synchronous lift. Advanced laser sensors in the LT50 enabled precise height adjustments, ensuring accurate placement of each module. These tools not only minimized fall risk, but helped maximize the fabricator’s efficiency.
Once elevated, the system safely held the component in place while it was connected to the ceiling. During the lifts, the fabricator worked ahead of Barnhart to ensure a constant flow of constructed areas ready to be lifted and connected. By working with the customer and leveraging Barnhart’s expert engineering, the team maximized safety, improved schedule and introduced new tools to market.