Collett Delivers Transformer Using Bridge Over Bridge System for Bicker Fen Substation

Collett, a leading name in specialist transport and heavy lift, has successfully completed the complex transport and installation of an 89.9 Tonne Hyosung transformer for National Grid’s Bicker Fen Substation in Lincolnshire.

The multi-phase operation involved sea freight, heavy transport, civil engineering works and specialist lifting techniques to overcome significant route constraints.

The transformer was loaded at Port of Rotterdam onto a 5bed5 trailer configuration and shipped to the Port of Immingham via RoRo ferry before being transported to Collett’s Goole Heavy Lift depot for interim storage and preparation ahead of final delivery.

From Goole, the 89-mile movement to Bicker Fen substation required detailed route planning, producing swept path analysis reports and coordination with multiple local authorities. The route included motorway, A-road and restricted rural sections, all of which were assessed in advance to ensure safe passage of the abnormal load.

A key engineering challenge was identified just 0.6 miles from the substation at Cowbridge over Hammond Beck, where structural assessment confirmed the bridge had a load capacity of only 3 Tonnes.

To overcome this restriction, Collett implemented a specialist bridge over bridge system, allowing the loaded transport configuration to safely travel over the structure without transferring the full weight to the bridge itself. The system was supported by engineered crane pads designed to withstand up to 50 Tonnes per square metre, enabling installation and recovery operations for the bridge system sections.

Extensive enabling works were also carried out along the final approach, including approximately 1.5 miles of temporary trackway to widen access and improve ground conditions for the transport movement.

The delivery was completed under police escort, with coordination from both South Yorkshire and Lincolnshire Police. Traffic management measures were implemented across key route sections, including controlled movements at Bicker Bar roundabout.

At site, Collett’s heavy lift team completed the transformer installation using jacking and skidding techniques. A 30-metre skid track was constructed ahead of the convoys arrival, allowing the transformer to be transferred from the trailer and carefully skidded into position above the plinth before being lowered into its final location with precision hydraulic jacking systems. Anti-vibration matting and positioning plates were used to ensure accurate alignment and long-term operational stability.

The project required close collaboration with a range of stakeholders, including structural engineers WSP, who assessed the Cowbridge bridge and AECOM, who supported crane pad design. Coordination was also undertaken with local authorities, landowners and civil engineering contractors throughout the enabling works phase.

The project was completed within programme, enabling National Grid to continue critical infrastructure works at Bicker Fen Substation and supporting wider energy network reinforcement in the region.