Heavy Duty Hydraulic Upender: 20-Ton Tunnel Segment Flipper

Country / Destination: Chengdu, Sichuan Province, China
End-User Client: Power Construction Corporation of China (PowerChina / Sinohydro Bureau 7)
Equipment Model: SJG20-90 Customized Heavy Duty Hydraulic Upender
Rated Load Capacity: 20,000 kg (44,092 lbs) continuous tilting payload
Cradle Platform Geometry: Massive L-shaped structure ( $3, 000 mm \times 4, 800 mm$ clamping platform + $4, 800 mm \times 7, 800 mm$ support platform)
Flipping Angle: 90° (Driven by dual hydraulic cylinders)
Workpiece Specifications: 3-meter long semi-circular concrete tunnel segments with outer diameters of $6.6 m$ , $7.2 m$ , and $7.7 m$
Maximum Elevated Height: Strictly limited below $8, 900 mm$ ( $29.20 ft$ ) at 90° maximum tilt
System Aesthetics: RAL Peacock Blue (PB11) finish with high-durability epoxy coating

This customized 20-ton Heavy Duty Hydraulic Upender (Model SJG20-90) has been engineered by our technical team to automate the vertical rotation of massive concrete shield tunnel segments. Our client, Sinohydro Bureau 7 under the Power Construction Corporation of China (PowerChina), is a leading state-owned infrastructure conglomerate specializing in mega-scale subway, hydro-tunnel, and municipal transit boring projects.

During the shield tunneling process, curved precast concrete lining segments (each weighing up to 10 tons) are transported horizontally. To assemble these into a complete, pressure-resistant circular tunnel ring with an outer diameter of up to 7.8 meters, two matching semi-circular segments must be placed together, welded, and bolted firmly. Once assembled horizontally, the entire 20-ton circular ring must be flipped 90 degrees vertically so it can be picked up by the tunnel boring machine’s (TBM) erector arms.

To handle this extremely heavy, high-impact process, we engineered a customized pit-mounted, low-profile hydraulic upender. This system integrates seamlessly into their TBM assembly workshop, designed in compliance with European EN 1570-1 safety requirements and ISO 4413 hydraulic fluid power standards to ensure absolute reliability. This heavy-duty system is an essential part of our premium engineering catalog of upenders and tilters .

Challenge & Solution

Challenge

The primary engineering challenge of this heavy infrastructure project was preventing structural deflection and securing the eccentric 20-ton load during its 90-degree transition. When two semi-circular segments are bolted together on the platform, they form a massive

 $Φ7.8 m$ ring. During tilting, the curved concrete structure is prone to lateral sliding or sliding along its radial axis.

We resolved this through precise mechanical and structural engineering:

Large-Radius Adjustable V-Groove: We engineered a specialized large-radius V-groove structure directly into the $3 \times 4.8 m$ clamping platform. This saddle is geometrically configured to support and self-center the curved outer profiles of the $6.6 m$ , $7.2 m$ , and $7.7 m$ diameter concrete segments.
Dual-Edge Bolt-Locking Slots: To securely clamp the concrete rings and prevent sliding under gravity during rotation, we pre-drilled two heavy-duty bolt-locking slots into the corresponding edges of the platform. This allows operators to run high-tensile tensioning bolts directly through the concrete segment flanges and anchor them firmly to the platform frame.
Ultra-Rigid Frame Steel (J30020010): To eliminate the risk of structural warping, the L-cradle framework was fabricated from thick, heavy-duty J30020010 mm rectangular structural steel tubes and a 4mm plate surface. This provides massive resistance against compound bending moments during the 5-minute rotation cycle.

Solution

Operating inside an active, low-ceiling subway segment assembly workshop presented our engineers with strict spatial constraints. At maximum 90-degree extension, the overall vertical height of the tilted $4.8 \times 7.8 m$ platform was strictly limited to under 8,900 mm (8.9 meters) to prevent any collision with the overhead traveling cranes.

To meet this clearance constraint, we designed a low-profile base chassis that recesses deep into the workshop floor. We fabricated the bottom framework to sit low in a custom-designed pit, minimizing the table’s self-height.

The hydraulic system utilizes a high-torque 15 kW power unit paired with dual high-capacity cylinders with a $Φ150 - Φ105 mm$ bore-to-rod ratio. The hydraulic lines are fitted with integrated pipeline explosion-proof safety valves and pilot-operated check valves, keeping the fluid pressurized and locked in place in case of a sudden hose tear.

The electrical system consists of an external 3-phase 380V, 50Hz control cabinet with high-quality Delixi components, complete with a wired handheld pendant. The control box wiring and signal cables are routed through tidy, covered stainless steel wire trays.

If your underground tunneling project or precast concrete plant requires a customized, high-capacity Heavy Duty Hydraulic Upender, please contact our engineering team to receive a free, factory-direct design consultation.

Technical Specifications

Parameter	Delivered Specification / Value (SJG20-90)
Model Designation	SJG20-90 Customized Heavy Duty Hydraulic Upender
Rated Load Capacity	20,000 kg (44,092 lbs) continuous tilting payload
Lifting Tilting Angle	90° (Dual-cylinder electro-hydraulic single-direction rollover)
Platform Table Dimensions	$3, 000 mm \times 4, 800 mm + 4, 800 mm \times 7, 800 mm$ ( $9.84 ft \times 15.74 ft + 15.74 ft \times 25.59 ft$ )
Compatible Ring Diameters	$Φ6.6 m$ , $Φ7.2 m$ , and $Φ7.7 m$ circular concrete segments
Lifting Table Self-Height	Ultra-low profile, recessed flush inside concrete pit
Max Elevated Height at 90°	$< 8, 900 mm$ ( $29.20 ft$ ) to clear crane clearance
Full Tilting Cycle Duration	$\leq 5$ minutes (Uniform speed, shock-free deceleration)
Platform Frame Steel Tubing	Extra heavy-wall rectangular steel J30020010 mm
Platform Deck Plate Thickness	4 mm (0.15 in) Solid Steel
Lifting Hydraulic Cylinders	Dual cylinders, Bore/Rod: $Φ150 - Φ105 mm$ with hard-chrome plated rods
Hydraulic Pump Motor Power	15.0 kW AC Power Pack (380V, 50Hz, 3P)
Segment Clamping Interface	Multi-radius V-grooves + dual-edge pre-drilled bolt slots
Hose & Cable Management	Fully enclosed layout inside protective covered heavy-duty wire trays
Electrical Components Brand	Delixi heavy industrial electrical components with wired pendant
Equipment Protective Paint	RAL Peacock Blue (PB11) Corrosion-Resistant Finish

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Heavy Duty Hydraulic Upender: 20-Ton Tunnel Segment Flipper

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