Customer: D S Smith Speciality Packaging – The UK’s foremost supplier of corrugated packaging products and related services.
Machine Type: Uteco Diamond HP815 printing machine. This is currently the largest size Uteco Diamond printing press in Europe.
Scope of Works: To design in full detail the “contract lift” of the new £5m packaging print line including:
- Lifting plans
- Floor loadings
- Access and full CAD drawings
- Sequencing lifts and working envelopes to meet with a fully detailed installation programme
- Lift by lift method statement/rigging studies and risk assessments for the works to be performed within a CDM construction site.
Machinery Schedule /description of works:-
• Following planning meetings on site and at the manufacturer’s works, Merritts undertook the design of the floor protection system required to maintain all floor loadings to below the permitted 5 tonnes per square m. This included those for the handling of the main print unit in a single unit of 51 tonnes, together with any loads from all of the wheels/rigger loads of vehicles and lifting equipment and the necessary foundation infilling/bridging required to permit vehicle and equipment to be positioned and operated within the site and to install the print line.
• The hydraulic gantry system was used to offload and install the main print unit into final position precisely on to the pre-installed machine sole plates.
• Further to the press installation we also received some 15 no specialist vehicle and 13.5m trailer loads containing the remaining major machine components. This included key parts weighing up to 18 tonnes, together with all of the ancillary items, which were offloaded to marshalling areas prior to final installation.
• The onsite handling and final positioning was performed within the confines of the new building and pre-installed overhead services. This was completed during an intensive 6 day working programme. This involved the rigging of components of up to 13.5m x 2.5m x 2.2m and 8 tonnes in weight which were then required to be installed over the 4m tall machine line and yet operate within the 9.5m internal profile of the building. This would have not been possible using mobile cranes. We therefore used our remote controlled lorry mounted cranes; in-house lifting modules and skilled personnel. Everything was completed to plan and without deviation from the method statement and CAD lifting study of the proposal.
• We also provided the trained and qualified labour, industrial forklifts and access equipment to facilitate the manufacturer’s engineers works up to the completion of the primary press installation, all of which were performed well within the planned schedule and within budget.