HONOR, COURAGE, COMMITMENT … AND LOTS OF PLANNING
Flyhouse is no stranger to large and challenging projects, but often the behind-the scenes requirements, deadlines, and extensive planning add an extra level of complexity.
Client Ask: Replace an existing automated rigging system without impacting the 197 foot x 36+ foot Battleship Replica permanently installed below. Fabricate a single custom drum hoist to replace three previous hoists with a more traditional rigging approach. Provide more opportunity for longevity by incorporating a custom access platform into the hoist design allowing easy inspection and regular maintenance. Fabricate and test the nearly 9000 lb structure in the Flyhouse shop, from welding, to handcrafted assembly, to writing the program code that operates the automation.
Flyhouse worked with Kupono Government Services on behalf of the US Navy for a Capping Ceremony Truss System installed at the Naval Station Great Lakes. We understood that managing the contract intricacies, administrative regulations, and adhering to the tight timeline would be key to the success of the project. While most contracts focus on the onsite installation time, this specialty project for a US government facility required a level of transparency unparalleled. Right from the start, our team took great care to outline all the hours needed for the behind-the-scenes logistics, often not discussed in detail during bid.
After a nearly nine-month selection process, Flyhouse was awarded the contract during the 3rd quarter of 2022 and went straight to work. We were able to finalize our custom system design, breakdown our milestones, and translate each item into the government required CDRL documentation. Next came a deep dive into the systems and software engineering process. Then in late summer 2023, we began in-house fabrication and were thrilled to finally put a year of planning into action! But we weren't just fabricating any hoist. This custom Flyhouse hoist was integrated into its own access platform, essentially creating a large enclosure and a safe walking surface with railings for use in daily system checks and maintenance. One single hoist replaced the three hoists that were previously needed to move the 150’ of truss required for the capping ceremony.
Naval Station Great Lakes By the Numbers:
5000
pound capacity hoist
15’3” x 7’5”
custom fabricated access platform integrated into hoist design
2
12” diameter by 3’3” length custom lathed drums
2400
feet of quarter inch cable
13
lifting lines
152
continuous linear feet of 12” box truss designed to suspend the following:
2
large projection screens, each 25’ wide x 17’9” high
2
US Flags each with an average size of 11-1/2’ wide x 6-1/2’ high
3
custom roller banners each with an average size of 9’ wide x 16’ high
1
nearby replica battleship simulator, measuring 197’ long x 36’ 7” high
