Challenge
The customer needed a portable proof load rig capable of testing aircraft tripod jacks ranging from 0.5 metres to 7.6 metres in height and up to 180 tonnes in load. The rig had to break down into manageable sections so it could be transported between service stations and reassembled quickly on site, all while staying within standard transport width limits.
The biggest challenge was achieving this portability without compromising structural integrity. Splitting the base plate into two transportable halves introduced significant engineering complexity because the joint had to carry very high compressive loads without distortion. The rig also needed to maintain accuracy, support universal mounting patterns and handle occasional overload conditions safely, protecting both operators and equipment.
Operator ergonomics were equally important. Connection points, alignment features and the adjustable height beam all had to be designed so that a single operator could configure the rig safely and repeatably across multiple tripod jack geometries.
In short: create a transportable modular test rig that performs like a permanent heavy duty installation under extreme loads.
How Amtek Tackled It
We began by mapping the full load path through the structure, focusing especially on the behaviour of the joint between the two base halves. Using detailed stress and deflection analysis, we evaluated load cases up to 1.5 times the working load limit to confirm the rig would remain stable under overload conditions as well as normal operation.
We developed a reinforced structural arrangement using high grade steel to maintain rigidity while keeping each modular component within handling limits. Joint interfaces were engineered with precision geometry to ensure correct alignment after reassembly and to maintain stiffness under compressive loading. The adjustable height beam was designed to accommodate the full tripod range and pitch circle patterns without compromising stability.
To validate our design assumptions, we conducted joint stiffness checks and deflection assessments to ensure the assembled rig behaved consistently after repeated install and remove cycles. The design was iterated repeatedly to refine critical areas, reduce stress concentrations and ensure deformation remained within acceptable limits.
Throughout development, we considered operator safety at every stage. Connection pins, load paths, tether points and working positions were arranged to keep personnel clear of high load areas, and the rig was designed to be set up by a single trained operator.
The Solution and Its Impact
Amtek delivered a modular, high capacity proof load test rig capable of safely applying loads up to 180 tonnes, with structural integrity verified through analysis up to 270 tonnes and ultimate strength validated to 405 tonnes.
Reliable proof load testing across multiple locations The rig can be transported within standard width limits, assembled on site and used without reliance on a fixed test facility.
Structural stiffness that protects equipment and operators Optimised load paths, reinforced geometry and validated joint performance ensure the rig maintains accuracy and stability under load.
True versatility for multiple tripod designs The adjustable beam and universal mounting configuration allow the rig to accommodate a wide range of tripod heights, foot placements and pitch circle diameters.
Improved efficiency and reduced downtime By bringing the test equipment to the jacks rather than transporting heavy jacks to a central facility, the customer significantly reduced handling time and operational delays.
Trust Amtek to deliver high-quality and reliable engineering solutions that drive innovation.
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