Projects & Case Studies· Remove and Replace ·Industrial
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At an aluminum plant in Foley, Alabama, Barnhart was tasked with removing and replacing a 150,000 lb., 50-year-old motor—a critical component for the facility’s operations.
A traditional approach would have required a massive crane and costly roof modifications, significantly extending the outage schedule. Instead, Barnhart delivered a smarter solution.
After laser scanning the area, our team engineered a custom system using a hydraulic platform trailer and a rotating gantry mounted with a girder and moving counterweight. This setup allowed the team to reach over, lift, and extract the motor components through an alleyway—without disrupting the roof structure.
The same system was then used to install the new motor, safely and efficiently. The counterweight atop the girder dynamically adjusted the center of gravity, providing stability throughout the lift.
Another example of how Barnhart delivers innovative solutions that reduce downtime, cut costs, and solve complex challenges in tight spaces.
80,000 Pound Kiln Installation Project
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Alternate Approach: One-Lift Vessel Removal
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Cost Effective Approach to Up-Ending and Down-Ending a Power Plant Generator
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Cutting Cost, Saving Time: Inside a Stabilizer Vessel Replacement Project
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Lifting & Setting a 200 Ton Concrete Cap on a Historic Span Bridge
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Non-Conventional Approach to Indiana Ball Mill Removal and Replacement Project
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Problems Arise: Crafting Solutions During a Successful Steel Mill Installation Project
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Safe and Efficient Rooftop Unit Installation
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Smarter Dryer Replacement Inside a Tight Paper Mill Layout
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Start to Finish: 200-Ton Caisson Transport
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Successful Completion of Industrial Mining Project During Time Sensitive Outage
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Using a Custom Lifting Beam to Replace Transformer Radiators
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Barnhart’s Knoxville Team Delivers Big
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135-Foot Ship Lift | Barnhart Heavy Lift Cranes Barge Loading & Marine Logistics
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160-Foot Conveyor Lift and Set | Barnhart Project Spotlight
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Custom Tools and Strand Jacks: Solving a Nuclear Outage Challenge
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Barnhart’s Big Lift: Semiconductor Mega-Project
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Barnhart’s 380K lbs Generator Transport Across 1,800 Miles
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Inside the Move: 400,000 Pounds of Engineering Precision
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Barnhart Data Center Tools: Safer, Faster Solutions for Complex Installs
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Building the Ultimate Video Display: A 750-Ton Project at Bristol Motor Speedway
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Designing a Cost Effective Solution for Installing Nuclear Feedwater Heaters
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Finding the Best Approach to Replace Stacked Heat Exchangers
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Innovative Engineering: Heat Exchanger Replacement Completed in One Shift
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Installing the World's Largest Four-Sided Video Screen
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Intricate Removal Process of a Nuclear Steam Dryer
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Kiln Swap in Tight Quarters
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More Than Movers and Lifters: Advanced Planning and Engineering
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Safely Tackle Tight Deadlines: Innovative Approach to Offloanding 5,000 Lb Generator
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Smart Planning, Safe Execution: Industrial Screener Swap in California
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Tackling Unplanned Delays with Innovative Solutions: Nuclear Reactor Head Replacement
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The Importance of Planning: Project Planning Saves Valuable Time
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Tight Airspace, Big Lift: Setting HVAC Units
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When Access is Tight, MOCCS Delivers: Pipe Replacement Project
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Restacking a 430 Ton Generator On-Site: Tailling Beam & Telescoping Hydraulic Gantry
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Combining Systems to Move Hard-to-Reach Parts
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Precision Tilt of 430-Ton Power Generator in Tight Clearance
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10 Components Moved, 4 Days Saved — Nuclear Success Story
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Critical Motor Remove & Replace with Drastically Reduced Downtime and Cost
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How Barnhart Removed and Replaced a 58' Deaerator Ahead of Schedule
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Innovative Approach for Converter Removal and Replacement
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Innovative Motor Removal with Limited Clearance
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Nuclear Plant Power Increase - Efficient Removal and Replacement of Equipment
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"So let's see what 36 axles and a million pounds looks like..."
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Barnhart’s Goldhofer Platform Trailers: Modular Power for Heavy Transport
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Completing Remove & Replace Days Ahead of Schedule with Custom Engineering
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Going the Distance: Transporting International Cargo Over 1,100 Miles
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Hauling a Huge Rotor Through Small Town Streets
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Hauling and Setting Multi-Story Refinery Modules
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Heaviest Cargo Ever Moved Across Mobile Bay
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How We Simplify Super Heavy Transport - Project Cargo Logistics
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If There's a Will, There's a Way: Transporting Oversized Loads at a Nuclear Power Station
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Italy to Illinois: Transport and Installation of Four Texas Towers
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Massive Coils Travel 49,000+ Accident-Free Miles
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Moving 100+ Ton Components Two Stories High and Ahead of Schedule
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Transport Over Rivers and Roads, Turbine Haul and Installation
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Transporting a Massive Component Through a Snowy Minnesota Town
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Turnkey Solutions for Project Cargo
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Using Custom Solutions for Over the Road Transport | Barnhart Heavy Transport
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