Holcim is one of the world’s largest suppliers of building materials and construction solutions, known for its commitment to sustainability and innovation. At one of its UK sites, Holcim operates machinery dedicated to the production of paving bricks. The equipment includes a mould-lifting process where heavy components need to be safely positioned within the machine. Previously, this operation relied on an old articulated jib crane. Over time, it became clear that the existing setup was not fit for purpose.
Project Summary
- Client: Holcim UK, a global leader in building materials and sustainable construction solutions
- Project: Design, manufacture, and installation of a telescopic runway beam
- Purpose: Replace an inefficient and unsafe articulated jib crane used in the brick moulding process
- Outcome: Improved safety, operational efficiency, and ease of use
- Completion Date: November 2025
- Location: Leighton Buzzard, Bedfordshire, UK
The Challenge
The existing articulated jib crane made safe, smooth operation difficult. When operators did not use the articulating arms in the correct combination across two axes, the crane could collide with the machine. The crane frequently came into contact with surrounding structures and equipment, creating potential safety hazards and operational inefficiencies. It also occupied more floor space than necessary, and it delivered loads to their destination inefficiently, slowing the whole process and interfering with the closing mechanism of the brick moulding machine.
Holcim required a solution that would eliminate these issues while integrating seamlessly into the existing workspace. Safety, reliability, and precision were essential priorities.
The Solution
Bramley Engineering designed, manufactured, delivered, and installed a bespoke telescopic runway beam system to replace the old articulated jib crane.
The new telescopic beam allows the operator to position the mould accurately within the machine, removing unnecessary movements, and easily retract the beam so the equipment can close safely. The design combines floor-mounted supports with fixings to the existing steelwork, ensuring a robust and space-efficient setup.
Every aspect of the system was engineered to work seamlessly with Holcim’s operational needs, taking into account the limited space, existing structure, and operational workflow. After installation, Bramley Engineering conducted full on-site proof load testing to confirm the system’s performance and safety.
The Results
Since its installation in November 2025, the new telescopic runway beam has brought clear improvements to operations at Holcim’s UK site:
- Enhanced safety: The retractable design eliminates the risk of accidental collisions.
- Greater efficiency: Operators can position moulds more quickly and accurately.
- Improved usability: The system provides smoother, more controlled movement compared to the previous setup.
“Bramley Engineering provided an excellent solution to a long-standing problem in our moulding process. The new telescopic runway beam is far safer and easier to use, and it’s made a noticeable difference to how efficiently we can carry out daily operations. The installation went smoothly, and the team were professional and supportive throughout.”
Conclusion
This project demonstrates how Bramley Engineering’s bespoke lifting solutions can improve operational performance and safety in heavy manufacturing environments. By replacing an outdated system with a precisely engineered telescopic runway beam, Holcim now benefits from a safer, more efficient process that supports continuous production.
Planning a crane or runway project?
We can survey, design, fabricate, and install a compliant solution that fits your duty, your bay, and your budget.
Email: enquiries@bramleyengineering.co.uk
Phone: 01525 375225
