THLG Heavy Haulers Cross Borders

Barnhart and Tradelossa Join Forces to Move Huge Turbines

By Breakbulk Staff

(4-minute read)

Two members of The Heavy Lift Group (THLG) joined forces to carry out what they describe as the largest land movement ever to cross the U.S.-Mexico border.

Barnhart was contracted to transport two steam turbine generators, four gas turbine generators and four gas turbines from a rail spur in Yuma, Arizona to two separate locations in Mexico – a complicated project that required close cooperation with customs officials in both countries.

“Barnhart, with support from Tradelossa, successfully transported two turbines of similar dimensions for the energy sector from Yuma, to two different locations – the city of San Luis Rio Colorado and the Delegation of González Ortega, Mexicali, both within the border state of Baja California, Mexico,” the companies told Breakbulk.

“The project was challenging and complex because it required two transportation operations and border crossings of two oversized loads weighing over 200 tons each, through two different routes and connecting two nations.

“Coordinating with customs authorities from both Mexico and the U.S. was a key aspect of the success of these operations. The goal was not only to ensure that all components reached their respective destinations in less than 24 hours, but also to ensure the integrity of both turbines, following the highest standards of quality and safety established by both companies.”

The first turbine, destined for the San Luis Rio Colorado Combined Cycle Power Plant, took a comparatively simple route from Yuma before heading south to the Mexican border.

The delivery of the second turbine was significantly more complex, however, since its final destination, the González Ortega Combined Cycle Power Plant, necessitated making the international crossing at the Calexico border post in California.

Reaching Gonzales Ortega would not be a simple task: extensive route analysis uncovered a deficient bridge on the route that could not be avoided. Responding to the challenge, Barnhart engineered and implemented a jump of the entire bridge structure using Barnhart’s 65-foot-long bridge jumper system, while the Tradelossa team provided the cranes and rigging crew to install and remove the bridge jump multiple times.

The adaptations were carefully designed to mitigate the impact of the heavy cargo, reducing the pressure of more than 200 tons on the bridge’s structure. The project was awarded to Barnhart on April 7, 2023. Hauling operations began in August 2023 and the last load delivered on January 31, 2024.

Planning and Preparation

During the planning and preparation phase of the project, Barnhart’s engineering and operations team determined it would be necessary to use equipment with the technical capabilities to overcome the obstacles and the physical conditions along the two routes.

“The response was the cutting-edge girder bridge equipment designed, engineered and manufactured by Barnhart, known as the GS800, originally deployed by Barnhart’s operational team in the North American city of Yuma,” the companies said.

“On the part of Tradelossa, movement was carried out with a prime mover – a specialized tractor to provide the necessary starting and pushing and pulling force to transport the colossal girder bridge structure and turbines throughout the Mexican side. Barnhart’s operators steered the transporter through tight turns and maneuvers, while Barnhart’s field supervisor was the primary point of contact for the transport.

“Each movement had to be planned; a schedule was made months in advance and, during this timeframe, key points such as the transport schedule, staff assignment and the request and processing of all permits and documentation necessary for the cargo’s crossing through the border, as well as entry into the plants, were defined.

“Similarly, Tradelossa’s expertise was required, with two key members acting as supervisors for all transfers, maneuvers and rigging operations carried out in the field.”

THLG Collaboration

This international project is an example of the close cooperation that has become a hallmark of THLG membership. The network was founded in 1987 by a number of West European heavy-lift operators in anticipation of the European single market. THLG has subsequently expanded internationally and now boasts members all around the world, including Barnhart (U.S.) and Tradelossa (Mexico).

“To achieve such a feat on the field, Barnhart contracted Tradelossa to provide pull truck/prime mover and operators and developed a high level of communication and operational symbiosis with Tradelossa,” the THLG members reflected.

“Tradelossa provided their motor carrier IDs for the Mexican authority, thereby providing an avenue to secure permits with the Mexico government. Additionally, Tradelossa provided expertise in coordinating and liaising with Mexican authorities during the permit application and review process.”

The companies added: “Before the start of operations, it was necessary not only to strengthen communication channels between each department involved, but also to consider different measures and solutions for possible setbacks and challenges that could have arisen when transporting each turbine – from its point of origin in American territory, crossing the border, and to the two destination power plants located within Mexican territory.

“The result was that each party fulfilled their commitments, maintaining a flow of communication between both teams, achieving an ideal execution and respecting all timeframes requested by our clients.”

Barnhart and Tradelossa will be exhibiting at Breakbulk Americas 2024.