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Case Study

Turning Table

JC Butko Engineering

JC Butko Engineering is a trusted NSW-based structural and mechanical engineering firm known for delivering complex fabrication, installation, and process equipment solutions, with extensive experience in structural steelwork, piping, and machinery support systems.

For the West Gate Tunnel Project, a critical $6.7 billion infrastructure initiative, JC Butko Engineering identified a workflow inefficiency in the LS Precast Benalla site’s turning table used for rotating concrete tunnel segments. They engaged Quantech Design to modify the machine, ensuring smoother, safer handling, and reduced segment damage during orientation changes.

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Challenges

Designing this bespoke solution for such a big project took some creative thinking.
 

  • Concrete Segment Damage - The existing turning tables required a forklift to remove tunnel segments after rotation, which often led to accidental damage. JC Butko Engineering needed a modification that would allow the dedicated crane attachment to pick up the segments directly, eliminating the damage risk.
     

  • Structural Complexity - Modifying the turning table was not straightforward. The new arms needed to be offset to provide the necessary clearance for the crane attachment, but this introduced additional bending and twisting loads into the structure. With only a small bolting footprint available on the existing arm, reaction forces were concentrated and required careful engineering consideration.
     

  • Compliance & Validation - The modified design had to be validated with engineering-grade finite element analysis (FEA) to ensure the new arms could handle operational loads without overstressing the existing structure. The work was carried out in line with principles of AS 4100 and relevant steel design standards.
     

  • Minimal On-Site Welding - To streamline installation and reduce disruption, the new arms were required to be fabricated off-site and bolted into place. This placed further importance on ensuring the bolted connections and interface with the existing arms were robust enough to carry the new loads.
     

  • Project Delivery - While there was no extreme urgency, the modifications needed to be delivered in a reasonable timeframe to keep the West Gate Tunnel Project’s production schedule on track.

Solution

We worked with JC Butko Engineering to solve the challenge.

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  • Targeted Arm Redesign - Quantech Design modified the turning table by cutting the trailing ends of the original arms and designing new offset arms that could be bolted onto the remaining structure. This offset configuration increased the spacing between arms, creating enough clearance for the crane attachment to directly lift the concrete tunnel segments.
     

  • Iterative Engineering Development - The new arms were designed from the ground up and refined through several rounds of engineering-grade finite element analysis (FEA). Particular focus was placed on the connection back into the existing structure, where the small mounting footprint created concentrated reaction forces. Design adjustments were made to the mounting plate and geometry to ensure stresses were reduced to acceptable levels.
     

  • Fabricated for Simple Installation - To minimise on-site welding, the arms were designed to be fabricated off-site and delivered as bolted assemblies. This allowed quick integration into the existing machine, reducing disruption to operations while ensuring structural reliability.
     

  • Collaborative Process - Quantech Design worked closely with JC Butko Engineering throughout the project. The client provided detailed insight into site operations, while concept designs were reviewed collaboratively to ensure the final solution balanced practical functionality with engineering integrity.

Results

The turning table modification delivered by Quantech Design provided JC Butko Engineering with a practical, robust, and efficient solution for the West Gate Tunnel Project. It was satisfying to come up with a pioneering solution to a unique problem. 
 

  • Reduced Segment Damage - By enabling the crane attachment to directly lift the tunnel segments from the turning table, the reliance on forklifts was eliminated, greatly reducing the risk of costly damage to concrete segments.
     

  • Improved Workflow Efficiency - The new process streamlined handling, allowing segments to be rotated and lifted in a single, smooth operation, improving production speed.
     

  • Validated Structural Performance - Engineering-grade FEA confirmed that the modified arms and bolted connections could safely withstand operational loads without overstressing the existing structure.
     

  • Seamless Integration - The offset arms were fabricated off-site and bolted into place with minimal disruption, ensuring the modification was implemented quickly and effectively.
     

  • Collaborative Outcome - Close collaboration with JC Butko Engineering ensured the solution not only solved the immediate problem but also integrated seamlessly into their existing processes.

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