Patrick Mechanical Ltd. was contracted to complete a high-risk crane rail installation within a smelter converter aisle. The work involved operating at significant heights, up to 120 feet, using aerial lifts and walking on steel frameworks. To maintain both productivity and safety, our team ran 24/7 operations with 12 workers per shift, supported by strong safety protocols and specialized tooling.
Key Solutions Delivered
- Custom in-house lifting tools were developed to raise localized sections of rail safely—minimizing exposure to overhead hazards.
- Thermite welding was used for precise, durable crane rail alignment.
- Streamlined shift reports and handoffs ensured consistent communication and smooth transitions between rotating crews.
- A dedicated dropped tools protocol was enforced to mitigate risk during overhead work.
- Field-based QA/QC checks confirmed accurate crane rail placement, improving overall quality control standards.
Lessons Learned
Every challenge pushed us to get better. Here’s what we took away:
- We enforced strict dropped tools protocols during elevated work, reducing risk and improving safety on-site.
- Our team used real-time QA/QC to confirm rail alignment and structural integrity—spotting issues before they became delays.
- We developed innovative lifting tools that made confined and high-risk lifting safer and more efficient.
- We maintained momentum across 24/7 shifts by documenting each shift clearly and communicating handoffs with precision.
- We delivered consistent results with Thermite welding, further proving its value in complex crane rail installations.
Results & Impact
Our project was completed ahead of schedule with zero safety incidents, showcasing our team’s expertise in both project execution and safety leadership. Across 3,699 man-hours, Patrick Mechanical delivered:
- Seamless coordination across round-the-clock shifts
- High-quality rail placement validated through field QA/QC
- Overflow work awarded from nearby contractors due to proven performance
- Elevated safety and quality standards for future smelter projects
Looking for a crane rail installation partner who delivers precision and safety under pressure?
Contact our team at estimating@patrickmechanical.ca or call (705) 692-3984 to learn more about how we support complex smelter and industrial projects.
