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Heavy Tandem LIFT

Terex® AC 1000 and AC 500-2 cranes tandem lift a 200-tonne bridge girder beam


kuwait, June 30th, 2014 – Highway infrastructure projects positively impact a growing community in multiple ways. They reduce congestion, allowing the increasing number of commuters to get to their destinations faster and more safely. These projects also boost commerce with other municipalities in the region, contributing to the success and sustained growth of a city.


The State of Kuwait has experienced significant growth over the years, in part due to an influx of people emigrating from other countries, and the epicenter of this expansion is Kuwait City. The State is currently investing in a highway expansion project that runs close to Kuwait City. While it will ease congestion, this new roadway more importantly expands a highway network that will facilitate the growth of interregional and international trade with the Gulf Cooperation Council (GCC) Countries.


However, it takes a lot of manpower and companies such as heavy lifting contractor Integrated Logistics Company, with its Terex® lifting equipment, to complete these projects and turn the highways into a reality.


Quick Mobilization

This State expansion project includes a number of bridge spans and interchanges with crossing roads. One such span near Kuwait City required the placement of a 200-tonne (220.5-US ton) steel girder beam to support the bridge span. Due to the length of the beam, installation required a tandem lift.


The bridge’s contractor called on Integrated to perform the delicate operation. "After studying the lift’s requirements, we immediately knew our Terex AC 1000 and AC 500-2 all terrain cranes were the right machines for the job," says Mr. Saleh Al Huwaidi, CEO of Integrated. "They have the capacity needed to safely install the beam, and they are quickly driven to the jobsite and are very maneuverable." Maneuverability was key for this pick, as both the jobsite and surrounding area were congested.


Both the eight-axle AC 500-2 crane, with its 56-m (183.7-ft) boom, and the nine-axle AC 1000 crane, with its 50-m (164-ft) boom, were driven from Integrated’s yard in Kuwait to the project site with the main boom installed. This significantly shortened crane set up time at the site and saved the company money. "Our eight-man crew was able to install the counterweight, rig the cranes and have them ready for the lift in one day," says Al Huwaidi.


The compact design of the two Terex cranes helped Integrated to quickly maneuver the city streets and congested jobsite. All-axle steering of the AC 1000 crane allowed the operator to effortlessly position the 1,200-tonne (1,320-US ton) crane for the lift.


Twenty flatbed trailers transported 388 tonnes (428 US tons) of counterweight plus accessories to the site over a two-day period. To simplify counterweight installation, Terex standardizes the weight and shape of these segments, so the same counterweight will work on either the AC 500 or AC 1000 crane.


"Our counterweight design allows the same weights to be used on all our superlift class crawler cranes as well as all terrain crane models ranging from the AC 350 to the AC 1000,” says Christian Kassner, senior manager sales & customer support for Terex Cranes. "This reduces transportation costs and simplifies counterweight logistics.”


Tandem Lift

Carrying half the beam load, the AC 1000 crane was rigged with 228 tonnes (252 US tons) of counterweight and a 250-tonne (275-US ton) hook block. Crews used 25.8 m (84.6 ft) of main boom length at a 9-m (29.5-ft) working radius to initially pick up the 4-m-tall x 2-m-wide (13.1-x 6.6-ft) beam. For installation, the crane lifted the beam to an 8-m (26.2-ft) height at a 17-m (55.8-ft) radius. "Even with the weight of the beam at this radius, the AC 1000 crane was at less than 73% of safe working load (SWL),” mentions Kassner.


The other half of this dynamic crane duo, the 500-tonne (600-USton) capacity AC 500-2 crane began lifting its 102.2-tonne (132.5-US ton) total lift weight using 24 m (78.7 ft) of main boom at a 7.5-m (24.6-ft) working radius. Equipped with 160 tonnes (176 US tons) of counterweight, the crane easily hoisted the beam into position at a 12.5-m (41-ft) radius, safely operating at less than 82% of SWL.


Crews successfully installed the 200-tonne (220-USton) bridge girder beam and began their work to de-rig both the AC 1000 and AC 500-2 all terrain cranes. Within a week of leaving the yard, both cranes were back at Integrated’s facility and ready for the next project.


"We chose to use mobile cranes for the project, since they are better for a single lift," says Al Huwaidi. "We chose the Terex cranes because the service is excellent and reliable, and Terex provides strong technical support to our maintenance team."


About the Terex® AC 1000 All Terrain Crane

The nine-axle Terex® AC 1000 is the world’s most powerful all terrain crane that can travel on public roads with its 50-m (164-ft) main boom attached. At 20.3-m (66.6-ft) long, the AC 1000 is remarkably compact and maneuverable for a 1,200-tonne (1,320-ton) capacity class crane. The machine can travel with its main boom on public roads to nearly any location in the world and has the fastest setup times of any crane in its category, thanks to its luffing jib erecting system. With its maximum system length of 163 m (534.8 ft), the wide selection of extensions and attachments for the unit have been designed for transportation on standard trailer trucks, eliminating the expensive and time-consuming process of obtaining permits and the requirement of special-purpose vehicles.


The AC 1000 crane is available with a 50- or 100-m (164- or 328-ft) main boom, which is equipped with a open-nose sheave that makes attaching additional boom segments fast and easy. This delivers short rigging times to reach a 100-m (328-ft) lifting height. In addition, the optional SSL system increases the machine’s lifting capacity for a variety of applications, including general construction, infrastructure, power plants, petrochemical industries, tower crane rigging and erection of wind turbines.


The ergonomically designed crane cab, which can be tilted up to 20° backwards, is equipped with an integrated IC-1 touchscreen control system. This system allows operators to have quick access to important information such as wind speed, wind direction, hook load, rated lifting capacity, reach, boom length, and calculated and actual outrigger loads by simply tapping the screen.


The Terex AC 1000 all terrain crane reaches travelling speeds of up to 80 km/h (49.7 mph). A variable-ratio steering system with active, speed-sensitive, electronically controlled rear axle power steering provides excellent maneuverability and cornering stability.


About the Terex® AC 500-2 All Terrain Crane

With a carrier just 17.1-m (56-ft) long, the Terex® AC 500-2 all terrain crane is the most compact eight-axle crane in its class. A maximum working height of 145.8 m (478 ft) can be achieved with a luffing fly jib. The crane offers enormous power across the full lifting capacity range, through features such as the improved design of the main boom cross-section and the reinforced sideways superlift system. The star-shaped outrigger layout helps to ensure the stability required.


Short setup times and the IC-1 control system's ease of use make for safe crane operations and comfortable working conditions. All load charts are stored in the system, and the right charts are automatically retrieved after specifying the relevant load, working radius, and other configuration data.


The crane is powered by the latest engine technology, delivering 480 kW / 653 hp at 1800 rpm. The carefully thought-out drive design provides outstanding transfer of engine power, yielding excellent performance on both the highway and the jobsite.


About Integrated Logistics Company  

Integrated Logistics is a leading company in heavy lift cargo handling, erection of heavy lifts, transportation of over dimensioned cargo and the supply of various types of construction and lifting equipment to support the oil and gas, fertilizer and petrochemical plant, steel structure, refinery, wind turbine, power and construction sector projects in the Gulf Cooperation Council (GCC) Countries. Integrated’s fleet exceeds 2000 units, which includes mobile cranes ranging from 25- to 1,200-tonne (28- to 1,323-ton), crawler cranes with capacities from 50- to 1600-tonnes (55- to 1,764-tons), 200 axle lines to transport the heavy lifts, a tower lifting gantry system of 1,100-tonne (1,102-ton) capacity and other construction equipment. Most of Integrated’s crane fleet consist of Terex cranes, including the high capacity CC 8800-1 crawler and AC 1000, AC 700, and AC 500-2 all terrain models.


With headquarters in Kuwait, Integrated has business hubs in Qatar, Saudi Arabia, Bahrain and the United Arab Emirates, employing more than 2500 people.


For more information on Integrated Logistics, visit


About Terex

Terex Corporation is a diversified global manufacturer of a broad range of equipment that is focused on delivering reliable, customer-driven solutions for many applications, including the construction, infrastructure, quarrying, mining, shipping, transportation, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms; Construction; Cranes; Material Handling & Port Solutions; and Materials Processing. Terex offers financial products and services to assist in the acquisition of equipment through Terex Financial Services. More information can be found at

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