Precision Lifting and Nighttime Assembly on Boston’s North Bank Bridge

[MikePhua]

The Manitowoc 2250 and Its Role in Urban Infrastructure
The Manitowoc 2250 crawler crane is a 300-ton class lattice boom crane designed for heavy lifting in confined or complex environments. Manufactured by Manitowoc Company, Inc., a Wisconsin-based firm with over a century of crane-building expertise, the 2250 has become a staple in bridge construction, industrial plant assembly, and marine infrastructure. Its modular boom system, high line pull, and advanced control systems make it ideal for lifting large structural components with precision.
The 2250 features a maximum boom length of 330 feet and can be configured with luffing jib attachments for extended reach. Its counterweight system and hydraulic controls allow for smooth, stable operation even under challenging conditions. Thousands of units have been deployed globally, and its reputation for reliability has made it a preferred choice for contractors working on high-stakes projects.
Terminology Annotation

• Superstructure Segment: A prefabricated portion of a bridge’s upper framework, typically including girders, deck panels, and connection plates.
  
• Fly the Piece: Crane operator slang for lifting and positioning a structural component into place.
  
• Bolt-Up: The process of securing structural elements using high-strength bolts, often requiring torque specifications and alignment checks.
  
• Cloud Bank: A dense mass of low-lying clouds that can obscure visibility and affect nighttime operations.
  

Nighttime Assembly of the North Bank Pedestrian Bridge
In the early hours of October 3, 2011, Barletta Heavy Division undertook the final assembly of the North Bank Pedestrian Bridge in Boston, Massachusetts. Working under clear skies after days of rain, the crew used their Manitowoc 2250 to lift and position three final superstructure segments. The operation was supported by Saugus Construction Corp., with coordinated rigging, bolting, and alignment executed under tight time constraints.
The bridge, designed to span a critical section of Boston’s waterfront, required precise placement of prefabricated steel segments. Each lift was sequenced to minimize sway and ensure bolt-hole alignment. As the final segment was prepared for lift around 4 AM, a sudden cloud bank rolled in from Boston Harbor, enveloping the site in fog and reducing visibility. Despite the challenge, the crew proceeded with caution, relying on radio communication and floodlighting to complete the lift safely.
A Story from the Field
One operator recalled the eerie silence as the fog settled over the harbor. “It was like working inside a cloud,” he said. “You couldn’t see the top of the boom, but you could feel the tension in the lines.” The final segment was flown into place with millimeter-level precision, bolted up, and secured before sunrise. The bridge opened weeks later, connecting Boston’s North Bank to the Charles River Esplanade, and quickly became a favorite for pedestrians and cyclists.
Equipment Coordination and Safety Protocols
Executing a multi-segment bridge lift at night requires:

• Pre-lift planning with detailed rigging diagrams and load charts
  
• Redundant communication systems including radios and hand signals
  
• Floodlighting calibrated to reduce glare and shadow distortion
  
• Weather monitoring for wind, fog, and temperature shifts
  
• Torque verification on all bolted connections
  

The Manitowoc 2250’s load moment indicator and boom angle sensors were critical in maintaining safe lift parameters. Operators adjusted boom angle and swing speed based on real-time feedback, ensuring that each segment was placed without overstressing the crane or structure.
Industry Trends and Urban Bridge Construction
Urban bridge projects increasingly rely on nighttime operations to minimize traffic disruption and maximize safety. In 2024, several cities adopted modular bridge designs that allow for rapid assembly using prefabricated segments. Cranes like the 2250 are often paired with self-propelled modular transporters (SPMTs) to move components into position before lift.
Boston’s North Bank Bridge is part of a broader trend toward pedestrian infrastructure that connects waterfronts, parks, and transit hubs. The bridge’s design incorporates weathering steel, LED lighting, and vibration-dampening joints to ensure longevity and user comfort.
Recommendations for Similar Projects
For contractors planning similar lifts:

• Use cranes with proven track records in urban environments
  
• Schedule lifts during low wind periods and monitor harbor conditions
  
• Employ high-visibility PPE and reflective rigging tags
  
• Conduct mock lifts or dry runs with dummy loads
  
• Document all bolt-up procedures and inspect connections post-lift
  

Conclusion
The final assembly of Boston’s North Bank Bridge showcased the precision and resilience of nighttime crane operations. With the Manitowoc 2250 at the heart of the lift, and a skilled crew navigating fog and fatigue, the project was completed with surgical accuracy. As cities continue to invest in pedestrian connectivity, the lessons from this lift—planning, coordination, and adaptability—remain essential for future infrastructure success.