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Hydraulic Strand Jack |
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Strand jacking is a construction process
whereby large pre-fabricated building sections are carefully lifted and precisely placed. Strand jacks
are jacks used to lift very heavy (20,000 tons or more with multiple jacks) loads for construction and
engineering purposes. |
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The Octamec Group has pioneered the use of
the Hydraulic Strand Jack technology in India when it constructed the largest span space frame
aircraft hangar for Air India in Mumbai. Ever since then, Octamec has successfully used the Strand
Jack technology for many of its projects including the new terminal building at Chandigarh airport,
the aircraft hangars at Shamshabad airport for Air India, Mas GMR among others.
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Strand jack technology can not only raise or
lower heavy loads but can do so within tight operational tolerances and over long distances. The use
of synchronised heavy lifting with strand jacks is now becoming a standard tool for construction of
projects. Strand jacks give the engineer more flexibility in the design of projects which otherwise may
not have been possible. Designs that were previously discounted for constructability reasons can now
be reconsidered as viable options. |
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What is a Strand Jack? |
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Strand jacks were invented in Europe in the
1970s as a development of post tensioning systems and are now used all over the world to erect
bridges, offshore structures, refineries, power stations, major buildings and other structures where the
use of conventional cranes is either uneconomic or impractical.
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A strand jack is a hollow hydraulic cylinder with a set of steel cables (the "strands" in the name)
passing through the open centre, each one passing through two clamps - one mounted to either end of
the cylinder. The jack operates in the manner of a caterpillar's walk: climbing (or descending) along
the strands by releasing the clamp at one end, expanding the cylinder, clamping there, releasing the
trailing end, contracting, and clamping the trailing end before starting over again. The real
significance of this device lies in the facility for precision control. The expansion/contraction can be
done at any speed, and paused at any location.
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How is it used? |
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Strand jacks can be used horizontally for
pulling objects and structures and widely used in the oil and gas industry for skidded loadouts, speeds
of up to 40m/hr and Oil rigs of 38,000T have been moved in this way from the place of construction
on to a barge.
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As strands can only act in tension, a strand jack cannot push a load and is primarily used as a lifting
device in the vertical direction. However, a strand jack can be used in any direction as long as tension
is maintained in the strands. |
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Working principle of the Hydraulic Strand jack: |
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The high tensile strands used in strand jacks
are of the same solid wire used in pre and post tensioned concrete. These strands are often run
through an additional manufacturing process to reduce their diameter further by flattening/rounding
slightly the outer wires to give the strand more circumferential contact area (Figure 1). The reduction
of diameter means more strands can be utilised within a given area although the sectional areas are
the same. Additionally the increased circumferential area allows more contact area with the collets
and hence less wear.
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Figure 1: Cross section — standard and
modified strand |
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Figure 2: Principle of operation |
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Figure 2 demonstrates the principle of operation of a strand jack when
raising a load. For clarity only one strand has been shown in the diagram. The capacity of a strand
jack is directly proportional to the number of strands used. For example, strand numbers can range
from a single strand to 55 strands in a 6600kN jack. Strands are usually 15.2mm in diameter although
18mm diameter strands are sometimes used. |
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With respect to Figure 2, the yellow and green sections indicate a
hollow hydraulic ram while the black shaded area represents high pressure hydraulic oil. The collets
are shaded red and the mating collet housing is shaded blue. |
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STRAND JACK OPERATION |
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Step 1. The bottom collets are closed and hold the
load while the main ram is retracted. The hydraulic oil is supplied to retract the ram while the top
collets are open and do not grip the strand. The load is stationary during this part of the cycle. |
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Step 2. The top collets are engaged and the
hydraulic oil is supplied to the other side of the piston causing the load to advance. While the load is
being raised the bottom collets are open and do not grip the strand. |
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Step 3. Repeat step 1. |
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Step 4. Repeat step 2. |
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When raising or lowering a load, a built-in displacement transducer
measures the movement of each strand jack. The central control system keeps track of all strand
jack displacements and corrects for an errors that may accumulate. While the operation
demonstrated in Figure 2 relates to raising a load, the lowering operation is very similar except that
the phasing of the collet operations is reversed. |
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The high pressure oil to operate the hydraulic ram is supplied by
hydraulic power packs which can be either electric or diesel powered. A sophisticated software
program controls the motion of each individual jack to provide an overall synchronised lift. Integrated
within each strand jack is a displacement transducer which measures the position of the hydraulic ram
piston. This allows the computer system to monitor the flow requirements to each jack. During
operation, all jack loads and lifting point positions are displayed on the screen of the control unit. |
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CROSS SECTION OF A HYDRAULIC
STRAND JACK |
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Used for Octamec Projects: |
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Chandigarh Airport |
| 2. GMR
Hangar |
| 3. NACIL
Hangar |
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| Model no. HSL700 |
SWL: 700 kN @ 205 bar
Test pressure: 245 bar
Strands: 7 x Ø 15.7mm
Weight: approx. 640 kg |
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| Supplier: Freight Wings Pvt. Ltd, Mumbai |
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STRAND JACKS USED IN BUILDING
CONSTRUCTION BY OCTAMEC |
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1. Erection of Chandigarh Airport Space frame terminal
building |
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| Assembly before lifting |
Strand jack with power pack |
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| Control panel |
Structure after lifting |
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2. Erection of Truss for Air India Hangar, Shamshabad
Airport |
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| Erection of assembled truss |
Strand jacks |
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STRAND JACK USED FOR RAISING/LOWERING
NON-VERTICAL LOADS |
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The construction methodology adopted for the Silleda viaduct in
Spain incorporated the use of strand jacks. As shown in figure below the main span is supported by
two reinforced concrete arches which span a river valley below. The two arches were constructed in
a near vertical position adjacent to the main span piers with a hinged joint constructed in the base of
each arch. After completion of both arches, they were then lowered/rotated into place with strand
jacks |
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The slender main piers could not sustain the bending forces induced
during the lowering process. To overcome these forces the piers were back stayed with pre-tensioned
multiple strands. |
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