FCC Recycling turned to Bramley Engineering for a bespoke jib crane solution that could meet the demands of a new maintenance operation at the Greatmoor facility, that their existing lifting equipment could not handle.
Project Summary
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Client: FCC Recycling (UK) Ltd, Greatmoor site, Buckinghamshire
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Challenge: Replace outdated lifting equipment that could no longer meet operational demands
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Solution: Design, fabrication and installation of a new 1500kg SWL slewing bespoke jib crane with structural reinforcement
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Key Features: 3D scan and CAD stress analysis, structural steelwork reinforcement, retrofitted motorised slewing mechanism
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Outcome: A safe, reliable lifting solution that is now fully integrated into FCC’s long-term maintenance process
At Bramley Engineering, as a specialist bespoke crane manufacturer, we’re used to tackling the tricky stuff. When FCC Recycling approached us with a problem at their Greatmoor facility in Buckinghamshire, we knew it would require some critical thinking and a bespoke solution designed from scratch.
Having worked with FCC for over five years across multiple projects and servicing their cranes under LOLER, they trusted us to design and deliver a system that could meet new operational demands while adhering to high safety standards.
Taking a Closer Look at the Problem
FCC’s ash extractor required regular servicing, which involved removing large and heavy components for inspection and maintenance. Their existing jib crane, however, had a limited Safe Working Load and restricted reach. As the equipment aged and maintenance became more involved, the existing lifting solution was no longer suitable.
Manual handling had become the fallback method, which presented serious health and safety concerns. A new solution was essential, both for compliance and for the efficiency of FCC’s maintenance operations.
A Solution Designed from the Ground Up
We started by conducting a full 3D scan of the space, giving us precise measurements and allowing us to model the whole setup in CAD. From there, we ran stress simulations to see how a new crane and its loads would impact the building’s existing steelwork.
It quickly became clear that the building’s existing structural steelwork would not be capable of supporting the load of the lift and the new bespoke jib crane. In response, we designed additional structural steelwork to reinforce the area, ensuring it could safely carry both the crane and its maximum load of 1500kg. The design was reviewed and validated by a structural engineer from McFarland Consulting to double-check every the details of the new solution and ensure it would safely withstand the demands of the new operation.
Solving Operational Constraints On Site
Following installation, it became apparent that the jib arm could not be slewed manually due to limited access around the unit. To overcome this, we designed and retrofitted a motorised slewing mechanism to the crane that could be operated by radio control.
Limit switches were then fitted to either side of the cranes supporting steelwork to prevent the newly motorised jib arm from overrunning into structural steelwork.
This wasn’t part of the original planned solution, but the end result was a crane that’s not just safe and effective, but could be operated smoothly and safely within a confined space with limited access.
What It Means for FCC
This new bespoke jib crane has completely changed how FCC approach ash extractor maintenance. Jobs that were previously impossible without risky workarounds are now done quickly and safely. It’s already part of their internal process documentation and will be used regularly moving forward.
Here’s what the new system has delivered:
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Safer lifting operations that remove the need for manual handling
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A stronger, custom-built support structure to suit the site
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A longer reach and higher lifting capacity
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Compliance with LOLER and modern H&S standards
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Seamless integration into ongoing maintenance routines
A Track Record of Solving Complex Problems
This project is a strong example of our ability to combine structural engineering, bespoke fabrication, and site-specific problem solving. It joins a growing list of tailored lifting solutions we have delivered for clients across multiple sectors. You can also explore other examples of our bespoke engineering work here:
Need help with your own lifting challenge?
We design and manufacture safe, compliant, and bespoke solutions to meet even the most complex site requirements.
Get in touch with our team today:
Email: enquiries@bramleyengineering.co.uk
Phone: 01525 375225
