Safety in Action: Crane and Hoisting Operations at the WMATA Northern Bus Garage Project

The successful installation of 13 girders at the Washington Metropolitan Area Transportation Authority (WMATA) Northern Bus Garage Reconstruction project exemplifies how precise planning and coordination led to the safe and successful execution of a crane and hoist operation. 

Originally built in 1906 as a streetcar storage facility, the reconstruction is transforming the historic landmark into a 10,000-ton steel-frame facility to support WMATA’s first zero-emission bus fleet. As part of this scope, 13 massive girders—each measuring 100 feet long and weighing up to 92,000 pounds—were recently hoisted by crane into place to form a structural component of the frame. 

As Clark’s Critical 8 framework flags cranes and hoisting as an element of work with elevated risk, the team deployed a specific action plan to ensure a safe execution: 

• Planning Ahead: From start to finish, Clark established preventative safety and quality assurance measures. During initial meetings, the team made specialized plans for the weight and measurements of the rigging to account for the girders’ size, including reviewing them with a third-party engineer.
• Navigating the City: Before the girders arrived on site, Clark worked extensively with city officials and steel manufacturer Owen Steel to plan their delivery and safe navigation through Washington, DC. Given the girders’ size, each one was delivered separately and then bolted and welded together on site.
• Lifting the Beams: Any miscalculated movement could cause the load to move out of balance, putting both safety and production at risk. Each girder was placed vertically on dunnage platforms, while the team attached chain binders to secure the beam in its vertical position and ensure proper balance.
• Conducting Inspections: Prior to lifting, the project team performed a final inspection of the lifting and hoisting equipment for any hazardous deficiencies and to confirm proper capacities and configurations.
• Communicating Effectively: Close coordination between Clark and steel erector Williams Steel Erection was essential. For efficiency and clarity, a single line of communication between the crane operator and foreman was crucial for the operator to make the proper movements and avoid endangering crews both on and off the ground.
• Securing the Girders: Once each girder approached the frame, standby crews in a set of aerial lifts on either side of the beam secured the beam to the bolted connection points. The lifts were a critical factor in assuring the safety of team members handling the girders, as the flexibility of the aerial lifts enabled them to efficiently secure the beams without the risk of being in their flight path. The seamless girder installation at the Northern Bus Garage was the culmination of 16 months of planning and extensive coordination between Clark and project partners. The project team’s meticulous attention to detail served to ensure the safety of all crew members, at every stage of this complex installation.