PLC Intelligent Hydraulic Heavy Load Skidding Trolley for Cross-Sea Pipe Gallery Module Installation
Introduction
The 392-ton module prepared for synchronized skidding using KIET's PLC-controlled hydraulic system.
In large-scale offshore and cross-sea infrastructure projects, moving oversized steel modules is rarely a simple transport task. It is a controlled engineering operation where lifting accuracy, structural stability, ground conditions, synchronization, and safety margins directly determine project success.
In a cross-sea pipe gallery project in Zhoushan, Zhejiang, a heavy lifting and transport engineering contractor faced a challenging installation scenario: a steel structure module measuring 38 m × 12 m × 8 m and weighing 392 tons had to be moved into its final installation position across a soft tidal flat construction area.
Conventional lifting equipment could not directly complete the work. Large cranes were restricted by ground bearing capacity, while floating cranes could not accurately position the module at the required installation point. The customer required a safer, more controllable, and more efficient heavy equipment moving solution.
KIET engineered and supplied 16 units of PLC Intelligent Hydraulic Heavy Load Skidding Trolleys, forming an integrated PLC hydraulic skidding system capable of synchronous lifting, precise load transfer, high-speed skidding, and safe positioning.
The result: a traditional skidding cycle of approximately two days per module was reduced to less than half a day, achieving around 75% efficiency improvement and providing a proven module skidding solution for complex offshore construction environments.
Industry Pain Points
Operating on bridge tracks over soft ground is a key advantage of the hydraulic skidding system in offshore projects.
Offshore module installation and cross-sea infrastructure construction often involve oversized structures, limited access, unstable ground, and tight project schedules. For contractors, the challenge is not only moving heavy loads, but moving them with repeatable precision and controlled risk.
In this project, several key difficulties had to be addressed:
- Oversized module dimensions: The steel module was 38 meters long, 12 meters wide, and 8 meters high, creating significant concerns around load distribution and deformation control.
- Heavy single-unit weight: At 392 tons, the module required a robust heavy load transport system with high safety redundancy.
- Soft tidal flat conditions: The construction site had limited bearing capacity, making conventional crane access difficult or impossible.
- Limited lifting and positioning space: Final installation required accurate alignment, not just rough relocation.
- High synchronization demand: Multiple support points had to lift and skid together to prevent torsion, tilt, or local structural stress.
- Schedule pressure: Traditional methods would extend project duration and increase equipment rental, labor, and risk management costs.
For large contractors, these are not isolated issues. Similar challenges are common in offshore pipe galleries, prefabricated bridge sections, petrochemical modules, shipyard structures, offshore platforms, and heavy industrial plant construction.
Why Traditional Lifting Methods Fail
While essential for assembly, large cranes can be impractical for the final, precise horizontal positioning of modules in complex site conditions.
For a module of this size and weight, traditional lifting methods can quickly reach their practical limits. Large crawler cranes require stable ground, sufficient working radius, and significant assembly space. In soft coastal or tidal flat areas, ground reinforcement can become expensive, time-consuming, and still may not provide adequate operational safety.
Floating cranes may be effective for offshore lifting, but they are highly dependent on water depth, tide conditions, wind, wave motion, and positioning tolerance. When the module must be transferred to an inland or semi-offshore final installation point, floating crane access may be restricted.
Multi-crane lifting also introduces synchronization challenges. Even a small mismatch between lifting points can create uneven stress, potentially causing deformation in large steel structures. For a 38-meter-long module, uncontrolled lifting variation can compromise structural integrity and installation accuracy.
The real challenge was achieving controlled lifting, synchronized movement, stable skidding, and precise final positioning under offshore construction constraints.
KIET Solution Overview
KIET developed a customized heavy load skidding system using 16 PLC Intelligent Hydraulic Heavy Load Skidding Trolleys. The system was designed to combine hydraulic lifting and horizontal skidding into one coordinated operation.
This solution enabled the contractor to complete a difficult offshore module movement safely and efficiently, while reducing dependence on large cranes and minimizing schedule risk.
How PLC Intelligent Hydraulic Skidding Trolley Works
Multiple hydraulic skidding trolleys are positioned at engineered support points to ensure balanced load distribution.
The KIET PLC Intelligent Hydraulic Heavy Load Skidding Trolley is designed for projects where heavy structures must be lifted slightly, transferred onto a track system, moved horizontally, and positioned accurately.
Track Arrangement: A temporary bridge track was arranged along the planned moving route to provide a stable pathway over soft tidal flat area.
Trolley Positioning: 16 trolleys were positioned at engineered support points based on structural load analysis.
Synchronous Lifting: PLC closed-loop control monitored displacement and pressure in real-time to maintain perfect balance.
Horizontal Skidding: After lifting, trolleys moved at 3 meters per minute with high stability.
Key Technical Advantages
PLC Synchronous Control
Continuous monitoring of lifting displacement and load pressure for coordinated movement.
Millimeter-Level Accuracy
Protects modules from twisting or deformation during long-span lifting.
Integrated Function
Combines lifting and skidding in one platform, simplifying the operation sequence.
75% Efficiency Gain
Reduces the skidding cycle significantly compared to traditional methods.
Why Customers Choose KIET
The pre-arranged bridge track provides a stable and controlled pathway, overcoming the challenges of soft or unstable ground.
Customers choose KIET because heavy load movement is not only about equipment supply. It requires engineering judgment, hydraulic system design capability, and site condition analysis.
- Proven experience in customized hydraulic lifting and skidding systems
- PLC intelligent control for multi-point synchronization
- Engineering support for complex heavy transport applications
- Ability to design solutions based on real working conditions
- Strong focus on safety, efficiency, and project execution
FAQ Section
Planning a heavy module movement, offshore installation, or complex industrial transport project?
KIET can help you design a safe, synchronized, and efficient heavy load skidding system based on your actual site conditions.