Precision and Power: Lifting a 2000-Ton Bridge in Christchurch

As part of Christchurch’s ambitious Southern Motorway expansion, one of the South Island’s most significant recent infrastructure projects is well underway. Fulton Hogan Civil (FHC) has taken the lead on constructing a brand new four-lane bridge that will carry motorists seamlessly over the ever-busy Barrington Street—eliminating congestion and setting the stage for smoother travel through the region.

But one phase of this bridge build presented a particularly formidable challenge: lifting the entire structure—2,000 tons in total—in a single, controlled operation before gently lowering it into its final position.

To tackle this, Fulton Hogan turned to HTC Christchurch. Known for their motto “making the hard job easy,” HTC engineered a lifting solution that blended power, precision, and safety.

The Tools Behind the Lift

After an initial site assessment and project walkthrough, HTC proposed a robust and elegant solution: twenty low-height Durapac 100-ton hydraulic cylinders. Each ram, despite measuring only 140mm in height and weighing a manageable 23kg, packs an immense amount of force—perfect for lifting such a heavy structure while staying within the tight vertical space available.

The combined lifting system, delivering 2,000 tons of force, was powered by a suite of high-performance Riken components. These included precision manifolds, shut-off valves, and a powerhouse Riken MP-15 three-phase pump to deliver consistent hydraulic pressure throughout the system.

To further ensure safety across the site, anti-burst valves were fitted across the entire hydraulic circuit. With over 200 metres of Polyflex hose snaking through the framework, these fail-safes were critical in preventing accidental system breaches during the lift.

Precision Monitoring in Real Time

For real-time feedback and fine control, HTC deployed an advanced electronic measuring system. Stroke sensors were fitted to key cylinders, feeding precise data back to digital displays. This allowed the lift manager to track progress millimetre by millimetre, ensuring a level, balanced rise across the entire bridge.

Planning Around a Busy Street and Wild Weather

Given that Barrington Street is a vital route through Christchurch, only a short road closure window was permitted. This meant that every detail of the lift had to be meticulously planned, tested, and rehearsed. HTC responded by assembling and stress-testing the complete system weeks in advance, leaving no room for surprises.

And surprises did come—just not on lift night. In the days leading up to the operation, Christchurch was hit by multiple earthquakes and an unexpected snowstorm. But the FHC team stayed the course. When the time came, they executed the lift flawlessly—and even finished ahead of schedule.

QUOTE FROM GRAEME JOHNSON AT FULTONS:

The team at HTC Christchurch are proudly providing all manner of lifting equipment and specialised tools backed up by onsite technical support to assist in the rebuild of their city.