Barnhart’s engineering team developed a custom-designed system to lift, stack and relocate 10 prefabricated modules for a project at a manufacturing site in Texas. Because the modules were constructed without lifting points, Barnhart first designed and fabricated five different types of lifting lugs, totaling 61, before the modules were transported to the facility.
Each module weighed 140,000 pounds. Each train consisted of four levels. Barnhart used a 500-ton Liebherr all-terrain crane to lift and stack the modules on its equipment.
Each stack measured 60' high x 60' long and weighed 480,000 pounds. Barnhart used a customized slide system to move the stacks of modules into the building.
The team utilized pull-up gantry jacks to lift the modules inside and then reconfigured them on powered gantry bases to transport them to their foundations. The project was completed within the allotted four weeks with zero incidents. It was awarded an SC&RA Rigging Job of the Year $750,000–$2 Million.