Precision Laser Cleaning (PLC) was engaged to assist with the repair and restoration of the boom girder on Ship-to-Shore Gantry Cranes within the Port of Brisbane. The project scope involved the removal of the Trolley Rail, corrosion and paint removal from the Boom Girder, and subsequent repairs and replacements. The goal was to restore the crane to ensure smooth trolley rail operation, eliminating irregularities that affected performance.
The Challenges
The project presented several unique challenges due to the crane’s height, overwater positioning, and strict environmental requirements. The client sought an efficient and effective solution that avoided extensive scaffolding, containment, and abrasive blasting – all while ensuring full compliance with EPA regulations regarding dust control over water.
Corrosion and Paint Removal Over Port Waterways: The crane structure was suspended directly over port waterways, requiring strict adherence to EPA guidelines to prevent debris or contaminants from entering the water. Traditional abrasive blasting or chemical treatments posed unacceptable environmental risks.
Height and Equipment Access: The cranes stand over 40 metres tall, making equipment and personnel access a key constraint. Traditional methods typically require extensive scaffolding or elevated work platforms (EWPs).
Time Constraints and Flexibility: The project had to be completed within tight timeframes while coordinating closely with the engineering team. A quick mobilisation and demobilisation process was essential to allow for seamless integration with ongoing repairs.
Weather Variability: As an outdoor project, exposure to the elements posed additional risks. The plan had to accommodate unpredictable weather conditions while maintaining progress and ensuring staff safety.
The Solution
PLC developed a tailored methodology to address these challenges and meet the project’s specific needs:
Dust and Debris Control Over Port Waterways: PLC deployed inline HEPA extraction systems to capture corrosion and paint fumes directly at the source. This eliminated the need for extensive scaffolding and containment structures, ensuring EPA compliance without risk of environmental contamination.
Height and Equipment Access: The lightweight and portable Netalux 300W Needle systems were selected for their versatility. This allowed all equipment and personnel to access the work area through the crane’s OEM Alimak lift, bypassing the need for expensive scaffolding or EWP hire.
Time and Flexibility: A dual-shift schedule was implemented, enabling 24-hour operations to meet the tight project timeline. The laser cleaning and repair work was conducted in sections, allowing the laser team to quickly mobilise and demobilise as needed. This flexibility allowed the engineering team to maintain control of the workflow without disruption.
Weather Adaptability: With no need for permanent structures or large scaffolding, PLC was able to safely pause operations during adverse weather conditions and swiftly remobilise once conditions improved. This approach ensured staff safety while keeping the project on track and maintaining momentum.
The Outcomes
PLC’s innovative laser cleaning methodology provided significant benefits for the refurbishment of the Ship-to-Shore Gantry Crane’s rail bed:
Complete Corrosion and Paint Removal: All corrosion and paint were effectively removed from the boom girder, restoring the surface in a safe, efficient manner.
EPA and Port Waterways Compliance: The use of direct inline extraction at the point of removal eliminated the need for abrasive or chemical methods, ensuring compliance with EPA regulations and protecting the surrounding waterways.
Height and Access Efficiency: By utilising the Netalux 300W Needle systems and the existing Alimak lift, PLC avoided the need for crane or EWP access. This streamlined the process, reducing project costs and minimising downtime.
Cost Savings: The ability to perform the work without scaffolding, EWP hire, or large containment structures resulted in significant cost savings. Highlighting the advantages of laser cleaning for similar overwater and high-access projects.
Safe and Incident-Free Execution: The project was completed without incident, reinforcing PLC’s commitment to health and safety even in complex, high-risk environments.
Laser Cleaning is a safe, cost-effective, more sustainable option for maritime industries
This project demonstrated the significant environmental and operational benefits of PLC’s laser cleaning services for the port and marine industries. By eliminating the need for hazardous chemicals and abrasive blasting, PLC provided a solution that is safer, more cost-effective, and environmentally responsible. The streamlined, repeatable process developed for this project establishes a model that can now be applied to future Ship-to-Shore crane refurbishments across the port.
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