Custom solutions for projects where delays are not an option

In large-scale renovation projects in the infrastructure sector, time is the scarcest resource. Work on bridges, locks, and viaducts almost always takes place within limited time windows, often on weekends or at night, because infrastructure cannot be shut down during the day. Within that timeframe, everything must be just right: the schedule, the machinery, the personnel, and the work methods.

It is precisely in these situations that it becomes clear that the standard approach is not always sufficient. Sometimes a project calls for a solution that does not yet exist.

Working under tight deadlines

During renovations of the deck surfaces of old bridges, wooden or concrete deck beams are periodically replaced. This is physically demanding work with little room for delays.

One of the biggest challenges is drilling precise holes in new beams. These holes must align exactly with the fastening points in the structure. Copying the old layout is rarely possible, because existing beams have warped after years of use or have broken off from the structure. The new beam must therefore first be fitted, marked, and only then machined.

Traditionally, this is done using manual drilling rigs, outdoors on the bridge, in varying weather conditions. It is a method that works, but it is physically demanding, prone to disruptions, and difficult to scale up when time is of the essence.

Mobile rigs as a solution

Another approach is to use a mobile drilling rig that is developed specifically for the project and can be deployed directly on site. Integrating the rig into an enclosed trailer creates a protected work environment that is unaffected by weather and environmental conditions.

This offers a number of concrete advantages. The process is standardized: each beam goes through the same steps in the same order, which reduces the risk of errors and makes the turnaround time per beam predictable. Dust and drill chips are extracted immediately, which benefits both employee health and compliance with environmental requirements. And because the system is fully prepared and tested before it is deployed on-site, virtually no technical support is needed during implementation.

An additional advantage is that the work method is accessible to temporary workers. In large renovation projects, it is common for crews to be supplemented with people who are unfamiliar with the specific installation. A well-equipped mobile workshop with clear instructions makes it possible to quickly get even those workers up to speed.

Custom construction as a solution to unique challenges

Not every project fits into a standard catalog. Sometimes the combination of requirements, the nature of the material, the location, the timeframe, and the available space is so specific that a custom solution is the only realistic option.

This calls for a different approach to collaboration. Instead of searching for an existing product that comes closest to meeting the needs, the process begins with a thorough analysis of the challenge. What are the constraints? Where can the most time be saved? What risks need to be managed? Based on these questions, a concept is developed, tested, and refined.

Modern visualization techniques play a useful role in this process. With photorealistic 3D models, a solution can be made concrete at an early stage, not only for the technical teams but also for clients and regulators who must approve the approach.

Preparation determines the outcome

In projects with a tight schedule, the execution itself is rarely the biggest risk. The risk lies in the preparation. Have the right tools been selected for the material? Have the employees been trained? Is there a backup plan for critical components? And has the installation been thoroughly tested before it is shipped to the site?

Thorough preparation makes it possible to work calmly and in a controlled manner during execution, even when the pressure is high. That is exactly what makes the difference between a project that is completed just in time and one that is finished ahead of schedule.

Curious to see how this works in practice? Read the case study about the drilling solution developed for the renovation of the Van Brienenoord Bridge’s deck: Drilling Solution for Work on the Van Brienenoord Bridge

Curious about what Van Dulst Techniek can do for your project? Contact us at verkoop@vandulst.nl or call 0180 510 455.