STAHL CraneSystems, a Columbus McKinnon Corporation (CMCO) company, and Bramley Engineering, a UK-based crane manufacturer, have joined forces to provide a safe, bespoke lifting solution with increased load capacity for the demanding maintenance of ash extraction systems at FCC Recycling's Greatmoor facility in Buckinghamshire, UK.
At the heart of the project is an ST chain hoist from STAHL CraneSystems, which has been integrated into the reinforced steel structure with the newly developed slewing crane. The modernized system is now changing the way FCC carries out maintenance on ash extraction systems in a confined and complex space.
Replacing the outdated, manually operated crane has created a future-proof, structurally validated system with motorized slewing control. The solution offers safe and efficient lifting performance with a load capacity of up to 1,500 kg. It enables greater reach and load capacity when maintaining the extractor. It also reduces manual effort and increases safety for maintenance teams. The new slewing crane system integrates into the existing building structure and now meets all legal requirements.
Increasing Loads and Ranges on the Extraction System
An extractor for ash from waste incineration processes must be serviced regularly. This involves removing and repositioning heavy components for inspection and repair. However, the original manually operated slewing crane had a relatively low load capacity and a short reach. Due to its age, it was no longer suitable for the increasing demands of the complex maintenance work in the confined environment. Proper mechanical handling was also becoming increasingly difficult, which is why teams increasingly resorted to manual lifting operations and improvised workarounds. This, in turn, was inefficient and did not meet the standard safety requirements.
For these reasons, Bramley Engineering was commissioned to develop a modern lifting solution that could safely handle loads of up to 1,500 kg around the ash extractor. The company works closely with customers to develop safe, functional and durable crane solutions – whether for heavy loads, confined spaces or more specialized applications.
Columbus McKinnon
Proven Chain Hoist from the Modular System
To ensure the required performance and reliability for the FCC extraction systems, Bramley Engineering selected a chain hoist from the ST range by STAHL CraneSystems as the central lifting component. This chain hoist is based on a modular system that allows many component combinations for individual solutions. Crane builders appreciate the robust ST electric chain hoists because they are powerful, reliable and undemanding in terms of maintenance and energy consumption.
Bramley Engineering first carried out a comprehensive 3D scan of the installation area, capturing the ash extractor, walkways and existing steel structure. This enabled detailed 3D modelling of the crane geometry, clearance checks and structural strength calculations to be carried out before manufacturing began. Subsequent analyses confirmed that the original structure could not support the new crane under full load.
Steel Support Structure with Structural Reinforcement
To solve the problem, Bramley designed and installed a steel support structure with structural reinforcement specially developed for the site to accommodate the jib crane with a load capacity of 1,500 kg. A chain hoist from the ST range by STAHL CraneSystems was selected to fit perfectly within this frame. Reliable performance under repeated maintenance loads and precise lifting near complex process equipment were key requirements.
The crane is compatible with a motorized slewing system and radio control. This was a decisive factor, as manual slewing is not practical due to the limited space around the ash extraction system. The operator must be able to position the jib safely and precisely from a clear location, away from confined areas.
Limit switches ensure that the safe slewing range is strictly adhered to. An overflow protection device prevents the jib from colliding with its complex surroundings. The clear layout of cables, controls and control devices facilitates maintenance. FCC now has a long-term, safe and standard-compliant lifting solution that is seamlessly integrated into its demanding maintenance processes.
