Reinstallation of two Cable Crane cables in Khersan 3 dam
Two long cables called “Cable Crane” that were used in Karun 4 concrete dam for the concreting stage of the dam body were successfully released by Payab Zamzam Company and reinstalled in Khersan 3 dam. These long cables, which are 97 mm in diameter, with a force of 180 tons, were stretched synchronously by two jacks of 400 tons capacity and installed on the local steel frame. In this operation, the cables are stretched about 70 meters to reach the desired profile. The operation was carried out with great care to prevent the parts from spinning and the force imbalance on the sides of the cable. The installation of these cables had previously been completely carried out by a German company that refused to release them from the Karun 4 dam and reinstall them in the Khersan 3 dam. Fortunately, this operation was entrusted to Payab Zamzam Company, and the necessary design for the execution of this operation was successfully carried out with the help of domestic equipment and personnel.
Due to the fact that if the main cable was suddenly released in the middle of the operation, many damages would be caused to the dam facilities, several measures were taken to ensure the safety factor in all stages of the work. For this reason, the number of strands on both sides of the part connected to the main cable (called the triangular piece) was increased to 12 and instead of 250-ton jacks, 400-ton jacks were used. In addition, two locking systems were added to the set of jacks so that at each stage of the cable pulling, the force in the system and the movement of the strands can be locked. In addition, a safety brake system was also used at the end of the strands to prevent any abnormal behavior during the operation.
The reinstallation of the last cable was completed in late December 2024 and the cables were delivered to the project employer.
Release of Two Cable Crane Cables in Karun 4 Dam
Two long cables called “Cable Crane” that were used in Karun 4 concrete dam for the concrete stage of the dam body construction were successfully released by Payab Zamzam Company and deployed on the ground. These long cables, which have a diameter of 97 mm, were stretched with 180 tons force and were stretched and released synchronously by two 400-ton jacks. This operation, which was previously carried out by a German company, was successfully carried out this time by the experts of Payab Zamzam Downstream with a fraction of the previous costs. It is planned that in the next stage, these cables will be reinstalled and stretched by Payab Zamzam in Khersan 3 dam.
Heavy Lifting operation in Northern Karaj Highway bridge
The Great Northern Karaj Bridge of is being built on the Karaj River near the old Bileghan Bridge. This box-type concrete bridge is designed with 3 long spans. The tall concrete foundations of this bridge have been constructed and the operation of installing the formwork (Shario) on the piers is underway to start the implementation of the decks. Formworks are available in 4 pieces in the process of being completed on two legs to run the decks from 4 sides. These formworks are very special and specially made for this purpose. Each formwork is 5.6 meters wide and 36 meters long. The floor part of the formwork, which has a weight of more than 80 tons, cannot be lifted by a tower crane and their lifting operations were entrusted to Payab Zamzam Company by the “Heavy Lifting” method.
Each formwork was lifted with 4 hydraulic jacks with the help of 4 bundles of 5-strand cables. During the lifting operations, their horizontality was checked and controlled by a two-axis electronic tilt meter manufactured by Payab Zamzam with an accuracy of 0.001 degrees. Lifting operation of 4 formworks finished in a month and all of the formworks are now at their places and working for deck concreting.
Mahan Air Hanger Roof Lift
The purpose of this project was to construct the hanger of Mahan Airline near Imam Khomeini International Airport. The hanger has a span of 150 meters, which in turn is a very large structure. In this project, the Strarch method was used to raise the roof of the nest, which is one of the unique innovative methods in the world. In this method, the roof of the hangar is completely executed at the accessible flat level (about 12 meters from the ground level) with light cranes, and with a stress operation, this roof becomes an arch in a few hours and is positioned at its main elevation level (32 meters). With this method, there is no need to use cranes with tall boom and high capacities.
In this method, due to the tension of the cable tendons that have been passed through the steel structure of the roof, the height of the 2000-ton metal roof of the hangar is increased by sliding from one side and arching by 23.5 meters. This very precise operation was carried out synchronously with 7 hydraulic jacks of 400 tons. Payab Zamzam team, with the help of its hydraulic equipment and in partnership with OVM Company, performed this project.
Lifting the metal beams of the railway bridge deck on the Tehran-Qom highway
Lifting metal or concrete beams in bridges is one of the things that is generally done due to the repair and replacement of bridge neoprenes. In this operation, without blocking the road and disrupting the traffic route, the bridge beams are raised and repair operations are carried out under the deck. After the completion of the operation, the beams will be returned to their previous position. The force of hydraulic jacks is used to lift the deck. The accuracy and simultaneity of the performance of the jacks in this type of project is of great importance.
In the present project, which was carried out on the Qom-Tehran axis, a number of steel beams were lifted from their place and successfully returned to their original position.
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