When helicopters replace cranes

The use of helicopters for transporting and raising loads in areas where access is difficult is already being considered by large construction companies for certain projects, and has motivated a few companies to develop this type of business in the country.

Imagine building a hydroelectric power plant in the Himalayas where construction materials, equipment and personnel must arrive at the construction site by air alone due to a lack of access roads designed for such a purpose. We’re talking about a real situation in which the use of helicopters was the only alternative considered for providing supplies to perform the work. This alternative, however, is not limited to projects with such an unusual profile. Brazilian construction companies are already considering the use of helicopters for handling cargo in areas of the country that are hard to reach, such as the Amazon region, for example.

The first experience of this kind in Brazil was during the construction of a section of the Coari-Urucu gas pipeline in the state of Amazonas, where the helicopter or aerial crane solution has simplified logistics and reduced the time required for completion of the project. Since access to the work sites was only possible by river barges, equipment and pipes were transported during the flood season, but had to wait for the dry season for the area be released for construction work. After the installation of the pipes, the fleet of equipment used in the operation had to wait for the next flood season to be removed from the site. In short: the use of helicopters for this purpose simplified the operation with a significant reduction in cost.

Other applications, however, can be rendered feasible, such as fighting forest fires, maintenance and replacement of offshore oil rig burners, and even rescue operations at sea, fighting forest fires and rescues. “One construction company is evaluating the use of helicopters to avoid having to open access roads for the installation of a 300 km stretch of power transmission lines that pass through an Indian reservation,” says Rogério Marques of Powerpack, a company in Brazil which represents Erickson Air-Crane - an operator and manufacturer of cargo helicopters and the leader in helicopter rentals in the United States.

Marques explains that this type of operation employs aircraft developed for military purposes which has been adapted to work in the transportation of cargo. In the case of Erickson (which uses helicopters manufactured by Sikorsky - a company known for its Blackhawk combat model and other aircraft used in Korea, Vietnam and Iraq), the helicopter has a load capacity of 9 tons or 12 tons and several accessories for moving a wide variety of cargo.

Feasibility of application

As a representative of Erickson (which belongs to the UTC Aerospace group that also controls helicopter manufacturer Sikorsky), Powerpack is prospecting for business opportunities for Erickson, which operates aircraft, as well as for the sale of such equipment to companies interested in hiring this type of service. “Due to the high cost of mobilization and demobilization of equipment, greater feasibility will come from developing a fixed base of operations in Brazil,” Marques ponders. He estimates that the country may already display a demand that can justify a local fleet of eight aircraft.

Among the aircraft’s distinctive features, the expert cites the cabin that is dedicated exclusively to controlling the handling of cargo and which provides greater visibility for the operator and precision in performing the work. With that, the helicopter becomes a flying crane, since it has the capacity to transport a complete transmission tower for assembly at the site of installation. “In addition, the helicopter has a system that prevents rotation of a load that could compromise its flight,” says João Luiz de Negreiros Guerra, also of Powerpack.

In the opinion of Rogério Marques, the cost of the operation alone would already justify the use of helicopters for hoisting generators and large air-conditioning units in buildings located on city streets with a high amount of vehicle traffic. When asked if the cost is not prohibitive, he replies: “That depends. How much does one hectare of forest burned down in a fire, or stopping Avenida Paulista (a major artery of São Paulo) for an hour cost?” To illustrate the efficiency of the helicopter in fighting fire, the specialist says the aircraft can pick up 10,000 liters of water in 30 seconds and spray 3,000 liters per second.

Pioneering operation

The benefits provided by this equipment are confirmed by Nilson Rocha, vice president of Helicargo - a company that has just entered the market of helicopter rentals for this purpose. “In addition, helicopters can be used in the assembly and maintenance of burners on offshore rigs and oil refineries; in the installation of wind turbines on wind farms; TV, radio and telephones towers; among other applications,” says Rocha.

Resulting from a partnership between helicopter operator Helipark and crane rental company Guindastec, the company invested in the purchase of a Russian-made Kamov Ka- 32A11BC with 5 tons of cargo capacity. Besides this equipment, which has already been certified by Brazil’s ANAC (National Civil Aviation Agency) for operation in Brazil, the company has a crew that is trained and ready to execute its first contract. Here, the expectations of the executive are positive, to the point that he can envision the possibility of acquiring another unit in the short term.

According to Rocha, the project calls for the investment of  R$ 25 million (US$ 13.5 million) in the acquisition of the first unit alone, in addition to another R$ 20 million (US$ 10.8 million) invested in the construction of a 2,800 m2 hangar, permits for the operation of an ‘air taxi’ service, and training of staff. “The operation combines the expertise of a helicopter operator with the expertise of a company that is specialized in handling cargo,” he says.

The aircraft that is being used is capable of lifting loads by a 70 m cable and has a range of up to 920 km at a speed of 260 km/h. Another key feature for the efficiency of the operation is that the aircraft has a configuration that differs from traditional models with a single main rotor and a tail rotor. This model has two coaxial main rotors which rotate in opposite directions. “This provides greater stability in hovering over tight, limited areas even under adverse conditions, and ensures precision for the execution of tasks that conventional helicopters would perform with great difficulty.” According to Rocha, the absence of a tail rotor also makes the helicopter more compact, safer and capable of operating in areas of 22 m x 22 m.