Construction methodology for vertical access installation in stations and shafts using Alimak climbing systems. Production rates vary based on shaft geometry, access conditions, and installation complexity.
Key Statistics:
- Average installation: 2-3 weeks/system
- Typical height: 20-60m
- Lifting capacity: 1-2 tonnes
- Best practice setup: 10-12 days
- Speed: 0.3-0.6 m/s
- Operating hours: 18-20/day
- Design life: Project duration
- Safety factor: 3:1
INTERNATIONAL EXAMPLES
| Country | Project | Height (m) | Type | Duration (days) | System | Contractor | Cost ($K) | Source |
|---|---|---|---|---|---|---|---|---|
| Australia | Metro Sydney | 45 | Twin | 14 | SC-65 | CPB | 280 | TfNSW |
| UK | Crossrail | 55 | Single | 16 | SC-45 | Balfour Beatty | 260 | Network Rail |
| Singapore | TEL | 38 | Twin | 12 | SC-65 | Samsung C&T | 290 | LTA |
| Hong Kong | MTR | 52 | Double | 15 | SC-100 | Leighton | 320 | MTR |
| Sweden | Stockholm | 42 | Single | 13 | SC-45 | Skanska | 250 | SL |
CONSTRUCTION METHODOLOGY (WEEKS):
Week 1:
- Site preparation
- Foundation works
- Base frame assembly
- Power installation
- Initial testing
Week 2:
- Mast installation
- Guide rail fixing
- Safety devices
- Initial testing
- Level certification
Week 3:
- Car installation
- Control systems
- Safety testing
- Operator training
- Handover
DAILY SEQUENCE:
- Base Installation:
- Foundation check
- Base frame leveling
- Anchor installation
- Power connection
- Initial testing
- Mast Installation:
- Section preparation
- Lifting operations
- Bolt torquing
- Guide alignment
- Progressive testing
- Car Installation:
- Assembly
- Control fitting
- Safety systems
- Load testing
- Certification
Note 1: Installation rates are indicative only.
Note 2: Rates vary based on:
- Shaft geometry
- Access conditions
- Weather impacts
- Interface requirements
- Safety protocols
Note 3: Installation calculation formula:
T = (BT × HF × AF × IF) + SC, where:
- BT = Base time
- HF = Height factor (1.1-1.4)
- AF = Access factor (1.0-1.3)
- IF = Interface factor (1.1-1.2)
- SC = Safety constant
TEAM COMPOSITION:
Installation Team:
- Supervisor (1)
- Riggers (2-3)
- Electricians (2)
- General labor (2-3)
- Safety officer (1)
Support Requirements:
- Mobile crane
- Power supply
- Tools/equipment
- Safety systems
- Testing equipment
QUALITY CONTROL:
Testing Requirements:
- Mechanical:
- Load testing
- Speed testing
- Brake testing
- Emergency systems
- Electrical:
- Power systems
- Controls
- Communications
- Safety circuits
Key Considerations:
- Foundation stability
- Power requirements
- Weather protection
- Emergency procedures
- Maintenance access
- Interface management
- Documentation needs
- Training requirements
Additional Safety Requirements:
- Fall protection
- Emergency rescue
- Communication systems
- Weather monitoring
- Access control
- Permit systems
- Daily inspections
- Weekly audits
DETAILED ALIMAK ANALYSIS BY TYPE AND HEIGHT
SINGLE CAGE SYSTEMS
| Type | Height (m) | Capacity (kg) | Installation (days) | Team Size | Cost ($K) | Daily Checks | Maintenance |
|---|---|---|---|---|---|---|---|
| SC-45 | 30-45 | 1000 | 12-14 | 8-10 | 240-280 | 2 hrs | Weekly |
| SC-65 | 40-60 | 1500 | 14-16 | 10-12 | 280-320 | 2.5 hrs | Weekly |
| SC-100 | 50-100 | 2000 | 16-18 | 12-14 | 320-380 | 3 hrs | Weekly |
TWIN CAGE SYSTEMS
| Type | Height (m) | Capacity (kg) | Installation (days) | Team Size | Cost ($K) | Daily Checks | Maintenance |
|---|---|---|---|---|---|---|---|
| TC-65 | 40-60 | 2×1500 | 16-18 | 12-14 | 380-420 | 3.5 hrs | Weekly |
| TC-100 | 50-100 | 2×2000 | 18-20 | 14-16 | 420-480 | 4 hrs | Weekly |
DETAILED INSTALLATION SEQUENCE:
Week 1 (Foundation & Base):
Day 1-2:
- Site survey
- Foundation preparation
- Power installation
- Safety setup
Day 3-4:
- Base frame assembly
- Level adjustments
- Anchor installation
- Initial testing
Day 5:
- Power connection
- Control cabinet
- Safety systems
- Documentation
Week 2 (Mast Installation):
Day 6-7:
- First mast sections
- Guide rail alignment
- Progressive testing
- Safety checks
Day 8-9:
- Continuing mast install
- Bracing systems
- Level checks
- Torque verification
Day 10:
- Final mast sections
- Top tie-ins
- System alignment
- Intermediate testing
Week 3 (Car & Commissioning):
Day 11-12:
- Car assembly
- Control systems
- Safety devices
- Initial testing
Day 13-14:
- Load testing
- Emergency systems
- Operator training
- Documentation
Day 15:
- Final inspection
- Certification
- Handover
- Training completion
QUALITY CONTROL CHECKLIST:
Foundation:
- Concrete strength: >40MPa
- Level tolerance: ±2mm
- Anchor torque: Specified value
- Ground capacity verified
Base Frame:
- Level: ±1mm
- Alignment: ±2mm
- Torque settings: 100%
- Power supply: Verified
Mast Sections:
- Verticality: 1:1000
- Bolt torque: Specified
- Guide alignment: ±0.5mm
- Bracing: 100% check
Car Installation:
- Safety devices: 100%
- Control systems: Full test
- Emergency stops: All points
- Communication: Verified
MAINTENANCE REQUIREMENTS:
Daily Checks:
- Brake test
- Safety systems
- Communication check
- Visual inspection
- Log completion
Weekly Maintenance:
- Guide rail check
- Motor inspection
- Cable inspection
- Brake adjustment
- Safety device test
Monthly Service:
- Full load test
- Control systems
- Emergency systems
- Structural check
- Documentation
Would you like specific details about:
- Emergency procedures
- Weather protection systems
- Interface management
- Training requirements
- Documentation systems
