🏗️ Issue 09 — Temporary Works & Erection Plant Risk

The Cableway Crane That Collapsed, and the Arch That Still Closed

A 42-year-old leased highline went down in high winds and cost two years. The arch it was built to serve closed to within 9.5mm anyway.

EE&HL Newsletter · August 2026 · Issue 9 · Free
The Hoover Dam Bypass concrete arch under construction, both cantilevered halves reaching toward the crown, supported by temporary stay cables from twin towers
The arch mid-construction, 2009. The two halves would close to within 9.5 mm of each other later that year.
Photo: Alan Stark, CC BY-SA 2.0, via Wikimedia Commons.
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The Project

890
ft
Above the Colorado River
1,060
ft
Twin-rib concrete arch span
106
segments
53 per rib, mostly 24-ft lifts
$240M
total cost
Jan 2005 – Oct 2010

(Mike O'Callaghan–Pat Tillman Memorial Bridge, Hoover Dam Bypass Project, Black Canyon, NV/AZ — bridge portion of the $240M project: ~$114M)

Hoover Dam was never built to carry the traffic that ended up crossing it. By the 1990s, roughly 14,000 vehicles a day — many of them trucks — were driving directly over the top of the dam on US 93, on a road with hairpin turns, blind curves, and no meaningful shoulder. Beyond the traffic-safety case, officials were also weighing dam and reservoir security: any serious incident on the dam crest sat directly above the intake towers and Lake Mead behind them, a concern that hardened further after 1995 and again after 2001. The fix was not a wider road. It was a new crossing entirely, roughly 1,500 feet downstream, spanning the Black Canyon 890 feet above the river — a height that would make it, on completion, the second-highest bridge in the United States.

The structure chosen used twin concrete arch ribs, 1,060 feet across, carrying a steel-composite deck above — the longest concrete arch in the United States, and the widest concrete arch in the Western Hemisphere. Building it meant solving a problem that had nothing to do with the arch's final geometry: how do you get workers, formwork, rebar, and wet concrete out to the middle of a 1,060-foot span, 890 feet above a river, with no falsework reaching the canyon floor and a federally protected recreation area beneath it?

The project's answer used two separate temporary systems, built by two separate logics. The first was a "high-line" cableway crane — roughly 2,500 feet of steel cable strung between two pairs of 330-foot lattice towers on the canyon rims, capable of hoisting workers and up to 50 tons of material across the gap. This was leased plant: a cableway system described in the project record as 42 years old at the time, refurbished and taken on a two-year, $105,000-a-month lease from American Bridge Co. It was the logistics spine of the whole job — concrete, rebar, formwork, and people moved across the canyon on it.

The second system was structural, not logistical: 88 temporary stay cables, run from temporary steel pylons atop the permanent piers, holding each arch rib segment in place as form travelers advanced it outward from both canyon walls toward the crown — a cable-stayed cantilever erection method, closing at the centre without ever touching the riverbed.

Both systems were "temporary works." Only one of them was part of the bridge's erection method. The other was rented haulage. That distinction is easy to state and easy to lose — and on this project, it is exactly where the commercial story sits.

Two systems, one project — leased plant vs. erection method

Two-system comparison for the Hoover Dam Bypass: the leased cableway crane plant (two pairs of 330-ft towers, ~2,500 ft span, collapsed 15 September 2006 in 50-55 mph wind, replacement operational January 2008) alongside the permanent arch erection method (88 temporary stay cables, 106 segments, crown closure August 2009 within 9.5 mm of centre)

Original diagram — EE&HL Network 2026

The Pattern & The Question

Why a cableway collapse and a fatal erection-method incident are two separate commercial events on the same project — and the one question to put to your own risk register.

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Marco Torri
Founder and Editor, EE&HL Network · Commercial intelligence for erection engineering & heavy lift