Replacing aging infrastructure is vital to maintaining reliable public transportation and increasing public safety. Phase I of the Park Avenue Viaduct Replacement Project exemplified this effort, delivering a rare urban infrastructure success with early completion and significant cost savings. Working with the MTA, Halmar International used prefabricated construction and two custom 200-ton Mi-Jack RTG cranes to efficiently replace aging viaduct sections in active rail territory – resulting in Phase I finishing $93 million under budget and 21 months ahead of schedule.
The Challenge: Rebuilding Critical Infrastructure Without Disrupting Service
Built more than 130 years ago, the Park Avenue Viaduct carries approximately 98% of all Metro-North train traffic across four main tracks into Grand Central Terminal. Spanning 1.25 miles and serving the Hudson, Harlem, and New Haven lines, the structure is a critical link for daily commuter travel – leaving no margin for extended outages or construction delays during replacement work.
Lifting Strategy for Phase I
During Phase I, crews replaced 8,240 feet of track across 128 bridge installations, which required lifting and positioning 190,000-lb bridge sections. Mi-Jack’s custom 200-ton gantry cranes enabled crews to efficiently lift out old steel and concrete deck segments and install prefabricated replacements within tightly controlled work windows, minimizing disruption of commuter services. Thanks to the planning and expertise of Halmar and the mobility, capacity, and precision of our RTG cranes, phase 1 concluded $93 million under budget and 21 months ahead of schedule.
Mike Kobbe, the estimating manager at Halmar International, reflects on the project: “The Estimating and Project team here at Halmar worked very early on with the Mi-Jack team to coordinate and design the custom MJ200 HD units used for the Park Ave Viaduct replacement. Measuring approximately 30’L x 50’H x 98’W, the machines required a complex erection procedure due to the need to straddle one of the busiest rail corridors in the Northeast to perform bridge replacement. The MJ200 HD Mi-Jack cranes allowed for half of the tracks on the viaduct to remain active during construction, unlike traditional cranes, which would have required foul time and more disruption to the traveling public. We were exceedingly impressed with the efficiency and reliability of the Mi-Jack RTG cranes.”
The two Mi-Jack MJ200HD gantry cranes were selected for their heavy-duty lifting capabilities (up to 200 US tons) and customization options. For this specific project, Mi-Jack’s MJ200HD cranes were customized the following ways:
- Active Track Operation: Designed to straddle the railway, enabling the replacement of 190,000-lb prefabricated bridge segments to happen at night, while Metro-North trains continued to run underneath during the day.
- Minimized footprint: The cranes also allowed for a reduced roadway footprint in dense North Manhattan, minimizing traffic disruption by narrowing closures from four lanes to two.
Moving Forward: Phase II Takes Shape
Following the successful completion of Phase I, which replaced the viaduct from East 115th Street to East 123rd Street, Phase II is now underway. This next phase will focus on replacing the viaduct from East 127th Street to mid-block between East 131st and East 132nd Streets, with completion expected in 2027.
To begin Phase II, the two Mi-Jack MJ200HD cranes had to be disassembled and relocated to East 128th Street – a complex operation requiring smaller cranes to lift and move the components. The top beams alone measure 94 feet in length and weigh approximately 83,000 pounds. Originally allotted two nights for the top beam removal, Mi-Jack completed the task in only one night. “Thanks to our Mi-Jack Engineering team and on-site technicians, the top beams were perfectly balanced and removed in one night—flawlessly,” said Luke Ninomiya, Aftermarket Sales Rep, Eastern Region. This precise relocation sets the stage for Phase II, ensuring the cranes are ready to support the continued replacement of the aging viaduct sections safely and efficiently.
“Thanks to our Mi-Jack Engineering team and on-site technicians, the top beams were perfectly balanced and removed in one night—flawlessly,”
-Luke Ninomiya
Aftermarket Sales Rep, Eastern Region
Mi-Jack Products: Built to Move Your Project Forward
Mi-Jack Products is proud to be a part of this major infrastructure project, and for the first phase coming in 21 months ahead of schedule. This project reflects our commitment to providing innovative, custom lifting solutions tailored to our customers’ unique applications.
To see how Mi-jack Products can help you bring your vision to life on your next project, contact our team today for more information. To explore how our Travelift cranes can bring innovation to your next project, contact our team today or visit Mi-Jack Products for more information.
