www.industryemea.com
16
'25
Written on Modified on
FCC Recycling upgrades lifting system for ash maintenance
Bespoke slewing crane with 1,500 kg capacity enables safer handling of heavy ash extractor components, implemented with support from Bramley Engineering and Columbus McKinnon.
www.cmco.com
Swing crane for maintaining ash extraction systems in confined spaces
FCC Recycling operates waste treatment and recycling facilities, including the Greatmoor site in Buckinghamshire, UK, where ash from waste incineration processes must be extracted and serviced at regular intervals. These activities involve handling heavy extractor components in a confined and technically complex environment.
At the Greatmoor facility, maintenance operations were increasingly constrained by an ageing, manually operated slewing crane. The system offered limited load capacity and insufficient reach, making it unsuitable for heavier components and evolving maintenance requirements. As a result, mechanical handling became difficult, and maintenance teams increasingly relied on manual lifting and improvised methods, raising safety risks and failing to meet current regulatory standards.
FCC set out to implement a lifting solution that would increase load capacity, improve reach around the extractor, reduce manual intervention, and integrate into the existing building structure without major civil modifications.
Designing a higher-capacity slewing crane
To meet these objectives, FCC commissioned Bramley Engineering, a UK-based crane manufacturer, to develop a bespoke slewing crane solution capable of safely handling loads of up to 1,500 kg. The design focused on improving lifting performance while ensuring safe operation in a confined space.
At the core of the system is an electric chain hoist from the ST range by STAHL CraneSystems, a Columbus McKinnon Corporation (CMCO) company. The hoist was selected as the primary lifting component due to its suitability for integration into custom crane designs and its ability to deliver consistent lifting performance under repeated maintenance loads. The modular design of the ST chain hoist allowed Bramley Engineering to configure the system to match the site’s spatial and operational constraints.
New lifting solution with the ST 20 chain hoist from STAHL CraneSystems
Digital planning and structural assessment
Prior to manufacturing, Bramley Engineering carried out a detailed 3D scan of the installation area, capturing the ash extractor, access walkways, and existing steel structure. This data was used to create a complete 3D model of the proposed crane, enabling clearance verification, load path analysis, and structural strength calculations.
These assessments showed that the original building structure could not support the new crane under maximum load conditions. To address this, Bramley Engineering designed and installed a reinforced steel support structure specifically developed for the site, providing the necessary load-bearing capacity for the slewing jib crane and integrated chain hoist.
Integrating the lifting system into confined spaces
The completed installation combines the reinforced steel structure with the slewing jib crane and the ST electric chain hoist from STAHL CraneSystems. The system provides a maximum lifting capacity of 1,500 kg and is designed for precise positioning close to process equipment.
Motorised slewing and radio control were critical design requirements, as manual rotation was not practical in the restricted space around the ash extraction system. Remote operation allows the crane to be positioned accurately from a safe location outside confined areas. Limit switches define the permitted slewing range, while overflow protection prevents unintended contact with surrounding infrastructure.
Structurally redesigned system with motorised slewing system and radio control
Operational impact and long-term compliance
By replacing the outdated manual crane, FCC has introduced a structurally validated lifting system that improves safety and efficiency during maintenance operations. The increased load capacity and extended reach allow heavy components to be handled mechanically, reducing physical strain on maintenance personnel and minimising reliance on manual workarounds.
The new system complies with current legal and safety requirements and is fully integrated into FCC’s maintenance processes. With the combination of a bespoke crane design and a proven electric chain hoist from STAHL CraneSystems, FCC now operates a durable, standard-compliant lifting solution suited to the long-term demands of ash extraction maintenance.
www.cmco.com
FCC Recycling operates waste treatment and recycling facilities, including the Greatmoor site in Buckinghamshire, UK, where ash from waste incineration processes must be extracted and serviced at regular intervals. These activities involve handling heavy extractor components in a confined and technically complex environment.
At the Greatmoor facility, maintenance operations were increasingly constrained by an ageing, manually operated slewing crane. The system offered limited load capacity and insufficient reach, making it unsuitable for heavier components and evolving maintenance requirements. As a result, mechanical handling became difficult, and maintenance teams increasingly relied on manual lifting and improvised methods, raising safety risks and failing to meet current regulatory standards.
FCC set out to implement a lifting solution that would increase load capacity, improve reach around the extractor, reduce manual intervention, and integrate into the existing building structure without major civil modifications.
Designing a higher-capacity slewing crane
To meet these objectives, FCC commissioned Bramley Engineering, a UK-based crane manufacturer, to develop a bespoke slewing crane solution capable of safely handling loads of up to 1,500 kg. The design focused on improving lifting performance while ensuring safe operation in a confined space.
At the core of the system is an electric chain hoist from the ST range by STAHL CraneSystems, a Columbus McKinnon Corporation (CMCO) company. The hoist was selected as the primary lifting component due to its suitability for integration into custom crane designs and its ability to deliver consistent lifting performance under repeated maintenance loads. The modular design of the ST chain hoist allowed Bramley Engineering to configure the system to match the site’s spatial and operational constraints.
New lifting solution with the ST 20 chain hoist from STAHL CraneSystems
Digital planning and structural assessment
Prior to manufacturing, Bramley Engineering carried out a detailed 3D scan of the installation area, capturing the ash extractor, access walkways, and existing steel structure. This data was used to create a complete 3D model of the proposed crane, enabling clearance verification, load path analysis, and structural strength calculations.
These assessments showed that the original building structure could not support the new crane under maximum load conditions. To address this, Bramley Engineering designed and installed a reinforced steel support structure specifically developed for the site, providing the necessary load-bearing capacity for the slewing jib crane and integrated chain hoist.
Integrating the lifting system into confined spaces
The completed installation combines the reinforced steel structure with the slewing jib crane and the ST electric chain hoist from STAHL CraneSystems. The system provides a maximum lifting capacity of 1,500 kg and is designed for precise positioning close to process equipment.
Motorised slewing and radio control were critical design requirements, as manual rotation was not practical in the restricted space around the ash extraction system. Remote operation allows the crane to be positioned accurately from a safe location outside confined areas. Limit switches define the permitted slewing range, while overflow protection prevents unintended contact with surrounding infrastructure.
Structurally redesigned system with motorised slewing system and radio control
Operational impact and long-term compliance
By replacing the outdated manual crane, FCC has introduced a structurally validated lifting system that improves safety and efficiency during maintenance operations. The increased load capacity and extended reach allow heavy components to be handled mechanically, reducing physical strain on maintenance personnel and minimising reliance on manual workarounds.
The new system complies with current legal and safety requirements and is fully integrated into FCC’s maintenance processes. With the combination of a bespoke crane design and a proven electric chain hoist from STAHL CraneSystems, FCC now operates a durable, standard-compliant lifting solution suited to the long-term demands of ash extraction maintenance.
www.cmco.com
