FCC Recycling has implemented a new lifting system at its Greatmoor energy-from-waste facility in Buckinghamshire, England, UK.
The new system, which replaces an outdated jib crane, aims to lower the risks associated with manual handling during ash extractor maintenance.
FCC Recycling tasked Bramley Engineering to create a lifting system for handling items weighing up to 1,500kg.
The project required operation within space constraints near an ash extractor and needed integration with the current building framework while adhering to regulatory standards.
Bramley Engineering chose the STAHL CraneSystems ST chain hoist from Columbus McKinnon as the main lifting device for this application.
The previous crane at the site had become inadequate due to limited capacity, restricted reach, and increasing maintenance demands.
As the equipment aged, manual handling methods took precedence, raising safety concerns and falling short of health and safety requirements.
Bramley commenced the project by performing a detailed 3D scan of the area around the ash extractor, including adjoining walkways and building steelwork.
This analysis informed the design of both the new jib crane and supplementary structural reinforcement.
The original support framework could not bear the upgraded crane’s full load; Bramley addressed this by installing additional steelwork.
Independent structural validation by McFarland Consulting confirmed compliance.
STAHL CraneSystems ST chain hoist was selected for its operational suitability in repetitive maintenance tasks near sensitive process equipment.
The hoist integrates with powered slewing controls operated by radio remote—a solution adopted after initial commissioning found that manual slewing was unfeasible due to space limitations around the ash extractor.
Limit switches and overtravel protection ensure that crane movement remains within safe boundaries while cable management details aid ease of ongoing maintenance.
The motorised slewing mechanism allows operators to manoeuvre loads without entering confined or hazardous areas.
The completed system aligned with LOLER regulations and relevant UK health and safety standards regarding lifting operations and manual handling.
With increased safe working capacity, enhanced reach, and integration into established maintenance procedures, FCC now operates under reduced manual handling risks and meets compliance obligations.
In July, STAHL CraneSystems launched the SXF wire rope hoist series, adding to its range of hoisting and crane components.
