Overview
JAK Hire was appointed to provide crane access for modular housing installation on a residential development site in Romford, Essex. The project involved lifting five modular housing units into position onto prepared groundworks, using a 250 tonne crane.
Due to access constraints, the crane and delivery vehicles could not approach from the main site entrance. Instead, it was determined that all lifting operations would need to be carried out from the rear of the site, using an existing car park area that was already showing signs of wear and deterioration.
JAK Hire was asked to provide a temporary ground protection solution that would create a stable and load bearing surface for both the crane and delivery vehicles, while minimising disruption to the site and ensuring the car park could be returned to use as quickly as possible.
The Challenge
Delivering safe and reliable crane access for modular housing installation required overcoming several key challenges on site.
Restricted Site Access
The layout of the development meant that the modular units could not be delivered and lifted into position via the main entrance. The only viable option was to position the crane at the rear of the site, using an existing car park. This required careful planning to ensure that both the crane and delivery vehicles could access the lifting area safely.
Existing Surface Condition
The car park selected for the crane setup was already showing signs of excessive wear and tear. The surface was not designed to support the load of a 250 tonne crane or the additional pressure created during lifting operations. Without protection, there was a significant risk of:
- Surface failure under load
- Further deterioration of the car park
- Increased reinstatement costs after the works
- Heavy Lifting Requirements
The installation of modular housing units involves significant lifting forces, particularly when using a crane of this size. The ground protection solution needed to:
- Distribute the load of the crane effectively
- Provide stability during lifting operations
- Support delivery vehicles transporting the units
- Tight Programme and Site Constraints
The timing of the works was critical. The car park needed to be taken out of use for the shortest possible period to minimise disruption to the site and surrounding area. A strict schedule was agreed:
- Installation of matting on Tuesday afternoon
- Crane operations on Wednesday and Thursday morning
- De-rigging and full removal of mats by Thursday afternoon
- This left very little margin for delays.
The Solution
JAK Hire designed and installed a temporary ground protection system using TuffTrak mats to create a stable and reinforced working area for the crane and delivery vehicles.
Crane Platform Installation
A dedicated crane platform was created using interlocking TuffTrak mats, providing a load-spreading surface capable of supporting the 250 tonne crane during lifting operations. The matting system:
- Distributed weight evenly across the existing car park
- Reduced point loading on weakened areas
- Provided a stable base for safe crane operation
Access for Delivery Vehicles
In addition to the crane pad, matting was installed to allow delivery vehicles carrying the modular units to access the lifting area safely. This ensured:
- Smooth vehicle movement across the site
- Protection of the existing surface
- Efficient positioning of units for lifting
Rapid Installation and Removal
Given the tight programme, speed and efficiency were critical. JAK Hire Hire worked to the agreed schedule:
- Matting installed on Tuesday afternoon
Crane fully operational on Wednesday
Continued lifting works on Thursday morning
Mats removed and site cleared by 5pm Thursday - This approach ensured that the car park was only out of use for a short, controlled period.
Coordination with Site Team
The works were carried out in collaboration with the site contractor, ensuring that installation, lifting operations and removal were fully aligned with the project timeline.
This level of coordination helped maintain efficiency across all stages of the project.
The Outcome
The project was completed successfully, with all modular units lifted into place safely and on schedule. By using TuffTrak ground protection mats, the site team was able to carry out heavy lifting operations without compromising the condition of the existing surface.
TuffTrak mats providing access for delivery vehicles and crane operations during modular unit installation.
Crane outriggers positioned on spreader pads and TuffTrak mats to distribute load and protect the surface.
TuffTrak mats used to create a stable crane platform with outrigger support for modular housing installation.
Customer Experience
“The site presented some real access challenges, particularly with the condition of the car park. The matting solution provided by JAK Hire allowed us to carry out the lifting operations safely and without causing further damage.”
Related Projects
Crane Access for Modular Construction Projects
Modular construction projects often require heavy lifting in areas not designed to support crane loads. JAK Hire provides crane access solutions for modular housing installation, creating stable working platforms and access routes using heavy duty ground protection mats.
From residential developments to large scale construction sites, our trackway systems allow cranes and delivery vehicles to operate safely while protecting the surfaces beneath. Contact JAK Hire today to discuss your crane access requirements.