Mammoet deploys SK crane for modular lifts at Zayed National Museum site

Estimated reading time: 4 minutes

The construction of the Zayed National Museum in Abu Dhabi’s Saadiyat Island has highlighted how ultra heavy lift engineering continues to reshape complex civil projects. Designed as the centerpiece of the Saadiyat Cultural District, the museum honors the legacy of Sheikh Zayed bin Sultan Al Nahyan while adding a structurally ambitious landmark to the UAE skyline.

Its defining architectural feature is a series of five wing shaped towers inspired by falconry. These structures are not purely aesthetic. They are engineered to enhance climate performance by drawing cooler air through the building. Delivering this design safely within an active construction zone required an installation strategy that balanced precision, safety, and schedule certainty.

Project stakeholders adopted a modular construction approach early. Four large pod shaped gallery units were prefabricated at ground level on site. These pods form the base of the wing structures and sit above a top lit central lobby recessed into the ground for thermal efficiency.

Fabricating at ground level reduced work at height and improved quality control. The challenge came in lifting and installing these irregular, heavy modules within a congested jobsite already populated with tower cranes and multiple trades.

The main contractor joint venture between BESIX and Trojan General Contracting engaged Mammoet during the early engineering phase to study lifting methodologies.

An initial plan considered deploying a large crawler crane. However, the elevated construction platform and restricted footprint meant extensive backfilling would be required to support crawler operations and superlift configuration. That solution risked disrupting civil works and tower crane movements.

Engineers instead proposed using the SK series crane, one of the largest capacity land based cranes in operation.

Positioned away from the busiest work zones, the SK crane provided the outreach needed to access lift points inside the structure while avoiding congestion. This allowed parallel construction activities to continue and kept critical lifts on schedule.

To adapt to evolving site conditions, the crane was rigged in two separate configurations.

It was first assembled in SK350 configuration, then relocated and reconfigured into SK190 format to operate within a smaller footprint. Both setups utilized a 135 metre main boom.

This phased rigging strategy demonstrated the system’s modularity. It also reduced the need for extensive ground preparation while maintaining lift performance.

Wind parameters formed a critical part of the engineered lift plan. Operations were executed only under wind speeds below 14 metres per second and with a decreasing forecast, ensuring structural and personnel safety.

The heaviest lift reached 612 tonnes at a working radius exceeding 150 metres. Such geometry would typically demand significant crawler crane repositioning.

Instead, the SK crane’s operating radius enabled pods to be picked directly from fabrication positions and installed with minimal relocations. This improved cycle time and reduced operational risk.

Ground bearing pressure was another key factor. The crane maintained a worst case load of 26.9 tonnes per square metre, avoiding excessive soil reinforcement.

Each pod required controlled rotation and tilting during installation due to its irregular geometry.

Mammoet engineered adjustable rigging systems using strand jacks. These allowed fine positioning adjustments from fabrication orientation to final installed alignment within tight tolerances.

This rigging methodology mirrors techniques used in stadium roof and airport terminal installations where architectural ambition collides with constructability.

Jack van den Brink, Managing Director AMEA at Mammoet, pointed to the company’s long regional track record.

“Since the UAE was established in 1971, the country has grown at an incredible pace and continues to lead through long term vision and innovation. Mammoet has been active in the UAE for almost 50 years, supporting customers across major energy and infrastructure projects, as well as landmark developments such as Burj Al Arab and Ain Dubai.”

By combining early engineering input, modular fabrication, and ultra heavy lift capacity, contractors were able to execute installation while maintaining momentum across the wider build program.

The museum has now opened to the public, featuring permanent galleries, temporary exhibitions, and outdoor spaces designed to connect visitors with the UAE’s heritage and global story.