Genie® Heavy Duty Boom lifts help complete intricate gantry crane finishing tasks on a tight schedule

Netherlands-based port operator BCTN signed a contract with the Rotterdam Port Authority for the operation of a new Container Transferium in Alblasserdam, near Rotterdam. Intended to relieve the A15 motorway of 200,000 TEU of containers per year, the project included the construction of a barge server to transfer containers, bulk goods and general cargo from the nearby barge port to the container terminal. The project was planned in several steps over a period of three months.

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After several weeks’ preparation, the barge server’s gantry was laid out in sections, assembled on the ground and lifted into position using a Terex® AC 500-2 and AC 700 all terrain cranes. With no more than a week to perform a series of intricate positioning and welding tasks, logistics providers Bolk Transport B.V. turned to Collé Rental & Sales for the equipment it needed to meet the deadline. Collé recommended two heavy duty Genie® S™-120 HD telescopic boom lifts, plus a Genie S-125 telescopic boom lift to provide the extra height needed to perform certain duties at the top of the 40 m barge server’s gantry.

Genie HD boom lifts: extremely reliable, tough and cost-effective

While providing the same smooth ease of operation and accurate positioning common to all Genie boom lifts, the protective features of Genie heavy duty boom lifts enable them to excel in harsh, salty and oxidizing conditions. They also stand up to weld slag, debris from cutting, impact damage and continuous intensive use in hostile environments.

“Thanks to the ability of Genie heavy duty boom lifts to withstand severe conditions, they are extremely reliable and cost-efficient to operate,” says Jan de Bos, Account Manager, Collé Rental & Sales, The Netherlands. “We own eight models and can certainly say that they are well-worth the investment.”

Built-in features adapted to challenging conditions

As part of their intensive week’s mission, the Genie S-125 boom lift and the two S-120 HD heavy duty units were relied on to help weld the barge server’s steel components together, connect its engine house, assemble and fix the engine house ladder to the main framework, and position the electric cables of the barge server’s lifting trolley into their respective reels.

Working intensively, often in conjunction with mobile cranes lifting heavy components, their high-strength, impact resistant steel platforms with padded bumpers, fire-resistant hose and cable sleeves and platform rotator shields, made the HD units particularly well suited to the task. In addition to being easy to operate, their sealed control box and joystick guards protected the operator controls from the accumulation of weld slag and debris.

Space to work comfortably

Finishing work on huge port cranes involves a wide range of tough and intricate jobs. Welding in particular requires close access and extremely precise movements. “In addition to their respective maximum working heights of 38.58 m (126.5 ft) and 40.15 m (131.7 ft) which provided the up-reach we needed, our operators found the machines particularly smooth and easy to use which helped save a lot of time,” says Mr. Hermann Kloppenburg, Project Supervisor for port crane manufacture Kocks Krane Gmbh. “The benefits of a 1.52 m (5 ft) long x 76 cm (2 ft 6 in) wide platform, which offered our operators the ability to work comfortably with all their tools, also avoided the need to descend the boom for multiple tool reloading sessions which was a great time saver.”

Smooth proportional controls

Performed in direct conjunction with mobile cranes, welding the engine house ladder is a particularly delicate process that requires careful coordination. A mobile crane and a Genie S-120 HD boom lift worked together with the former lifting up the ladder sections, and the latter raising two operators to position and weld the ladder sections onto the gantry. “This job can be very time-consuming. However, as a result of the Genie S-120 HD and Genie S-125 boom lifts’ intuitive proportional joystick controls, our operators handled this high-precision task easily and accurately” says Mr. Kloppenburg.

Safe, steady and precise

Once the 60 to engine house was positioned by two mobile cranes, the two Genie S-120 HD boom lifts then helped to connect its electric cables to the lower part of the bridge boom at a height of about 25 m (82 ft). “This job would simply not have been safe for our operators to handle from a mobile crane,” says Mr. Kloppenburg. “The Genie S-120 HD boom lifts proved extremely sturdy and stable which provided our operators the steady surface they needed to work confidently and productively.”

Time-saving full height drive function

The final stage of the job involved positioning the electric cables of the barge server’s lifting trolley. “This job involves threading the electric cables from the engine house into the cable reels that feed the lifting trolley,” explains Mr. Kloppenburg. “In addition to the smooth, accurate positioning provided by their proportional controls, the machines’ full-height drive function enabled our operators to move from one end of the gantry to the other without descending the boom. This was another advantage that enabled them to progress rapidly and succeed in completing the job within our deadline.”

About Genie® Heavy Duty Boom Lifts, and the Genie Deluxe Hostile Environment Kit

From steel construction, shipyard applications or applications on rocky hillsides, whenever additional protection is required Genie® S™-100 HD and S™-120 HD Heavy Duty boom lifts provide the right balance of high quality, productivity and great value.

Platforms utilize high-strength square steel tubing and padded bumpers for impact resistance. Their steel mesh surround also better retains dropped tools and resists weld slag. The steel platform rotator shield prevents weld slag and debris from accumulating on platform hoses, wires and the hydraulic rotator.

The steel-covered cable and hose track is mounted on the top of the boom to prevent impact damage. All exterior hoses and cables have fire-resistant sleeves. With joystick guards, a sealed control box cover and angled control box lid, operator controls are not just easy to use - they are also protected from weld slag and the accumulation of debris. Steel turntable covers resist impact for a longer service life. Large, removable service doors provide excellent full-engine service access. Lifting points make lifting the machine simple and easy.

All models include a fire extinguisher carriage located on the chassis, and come with solid, rough terrain tyres for outstanding performance. The 250-litre steel fuel tank allows continuous operation for up to 28 hours, reducing refills. The extra-large drain port facilitates draining and cleaning, and the visual fuel gauge simplifies refilling by making it easier to see the fuel level.

The Genie Deluxe Hostile Environment Kit is a factory-installed option that protects a wide range of Genie Z™ and ZX™ series articulating booms lifts, S™-series telescopic booms lifts and the Genie SX-180 boom lift from work in tough conditions. The Genie Deluxe Hostile Environment Kit includes cylinder bellows, boom wiper seals, turntable shield, ring gear guard and air pre-cleaner according to specific models.