Bramley Engineering

24 Hour Rapid Response Penstock Recovery: Case Study

Graham Bramley — Mon, 02 Mar 2026 12:41:31 +0000

A live sewage treatment works in London faced an urgent operational risk when a penstock seized and could not be released with any on-site recovery methods. With flows backing up, the site needed a safe, controlled way to free the penstock quickly.

Bramley Engineering stepped in with a rapid-response design, manufacturing a bespoke recovery solution to free the penstock. We delivered a purpose-made device, including a drilling jig, lifting bar, and two load-spreading gusset plates in a 24-hour turnaround, enabling the penstock to be opened in stages, bringing the situation back under control.

Project Summary

Client: Gel Engineering
Project: Design and manufacture of a bespoke emergency penstock recovery device, including a drilling jig, lifting bar, and split load-spreading bracing gusset plates
Purpose: Provide a safe method to release a seized penstock when conventional recovery methods fail
Turnaround: 24 hours from concept to delivery
Location: Live sewage treatment works

The Challenge

Gel Engineering were already on site carrying out an unrelated task when an operational issue developed with a penstock that could no longer be moved. The actuator mechanism had failed, and it normally rotates a specialist drive nut within the actuator housing. That nut engages with a vertical threaded bar, which is directly connected to the penstock gate. As the nut rotates, it drives the threaded bar up or down, raising or lowering the penstock to control water flow. With the actuator inoperative, flows began to back up and the situation was escalating quickly.

The team exhausted all practical options on site, including attempts using lifting equipment such as a 10 tonne jib crane, but the penstock remained stuck. A safe, effective recovery method was needed urgently.

Engineering Challenges

Releasing the penstock was not simply a case of applying more force. The recovery method had to deal with a significant load and avoid creating further problems.

High recovery loads: Estimated at approximately 20 tonnes due to hydrostatic pressure acting on the penstock.
Failed actuator drive: The actuator mechanism had broken internally, preventing rotation of the drive nut. The threaded spindle itself was structurally adequate but could no longer be driven in the intended manner.
No time for survey or scanning: There was no opportunity for a return visit or 3D scan, so the solution had to be developed using available dimensions and site observations.
Speed and material constraints: The design needed to utilise materials available in-house or from local suppliers the same day.

The Solution

Step 1: The initial concept

A lifting bar was the first logical step, drilled through the existing penstock actuator spindle, as the team could not get sufficient grip required on the spindle itself. After modelling the forces in CAD, it was clear that the additional lifting bar would not be strong enough to withstand the physics of the lifting operation and would likely bend and break, so a more robust solution was required. Additional support gusset plates were designed to reinforce the lifting bar from above.

Step 2: Create a secure fixing point with a drilling jig

To get proper grip and apply load safely, we designed a purpose-made drilling jig to drill accurately through the penstock actuator spindle. This created a secure fixing point for the bespoke recovery device, allowing controlled lifting forces to be applied without slipping.

Step 3: Engineer the supporting gusset plates

We designed bespoke bracing gusset plates that support the bar from above and spread the load safely, applying forces inwards towards the spindle rather than up which would likely cause the bar to deform and break.

The final arrangement provided a working tolerance of 10 tonnes per side, giving 20 tonnes total support across the gusset plates and bar to match the forces required for recovery.

Step 4: Manufacture at speed with materials available

Speed was critical, and the design was constrained by what materials were immediately available. The solution was engineered around stock on hand and same-day supply for maximum speed.

Step 5: LOLER-standard testing before delivery

Before it left our workshop, the equipment was tested to LOLER standard to confirm it was safe and fit for purpose.

Step 6: Controlled recovery on site

Using the bespoke recovery device fitted to the penstock actuator spindle, alongside a pair of jacks to lift the penstock, the team were able to release it and open it progressively in stages. This improved control during the operation and reduced risk compared with a single high-force attempt.

The Results

Penstock successfully released after conventional methods had failed
Controlled staged opening improved safety and stability during the recovery
Escalation avoided on a live sewage treatment site, reducing wider operational risk
24-hour concept-to-delivery turnaround supported an urgent, time-critical response
The tool can remain on site as a failsafe recovery option for future incidents

What Gel Engineering said:

“From the earliest stages of the project, Bramley Engineering proved to be an invaluable partner, bringing technical expertise, innovation, and a highly collaborative approach.

Bramley Engineering developed robust, practical, and compliant solutions that addressed both the operational requirements of the installation and the complex site constraints.

Equally impressive was their role in the installation phase, where their team worked efficiently, safely, and collaboratively with all stakeholders to ensure smooth delivery on site.

Bramley Engineering’s end-to-end capability, from scanning and design through to fabrication, installation, and regulatory support, demonstrates their value as a trusted and reliable delivery partner. GEL Engineering would not hesitate to recommend Bramley Engineering and looks forward to continuing our successful working relationship on future projects.”

– Robert Hoban, Contracts Manager

Conclusion

Working closely with Gel Engineering, our team moved quickly and collaboratively from problem definition to a safe, workable design, then straight into manufacture and LOLER-standard testing. By modelling the forces first and engineering around the real limitations on site, we delivered a compact recovery solution within 24 hours that helped stabilise operations and provided a practical failsafe option for the future.

Let’s collaborate on your next lifting solution

If you have a lifting, recovery or access challenge that needs a practical, site-ready solution, we can design and manufacture bespoke equipment quickly, then test and certify it so your team can use it with confidence.

Email: enquiries@bramleyengineering.co.uk

Phone: 01525 375225

Case Study: Weir Penstock Rescue Gantry and Steelwork for Thames Water

Graham Bramley — Thu, 22 Jan 2026 13:39:27 +0000

A Thames Water sewage treatment works needed a more reliable way to access and operate a weir penstock at their inlet channel and storm collection chamber, where incoming flows are managed and controlled before being directed through the site. When the hydraulic actuator failed (used to lift the penstock), the team required a safe rescue method to lift the penstock quickly, without unnecessary disruption to site operations.

Bramley Engineering designed, manufactured and installed a bespoke monorail rescue gantry and access steelwork to provide safe, compliant 24/7 access and significantly reduce downtime.

Project Summary

Client: Thames Water
Project: Design, manufacture and installation of a weir penstock rescue gantry, access steelwork, removable access bridge and an integrated chain block hoist system.
Purpose: Provide a reliable method to lift the penstock when the hydraulic actuator fails, and allow safe access to and operation of the penstock at all times.
Outcome: 24/7 access, reduced operational downtime, and prevent reliance on mobile crane call-outs when existing systems fail.
Completion Date: December 2025
Location: Hogsmill, South London, UK

The Challenge

The Thames Water had a recurring issue with the weir penstock hydraulic actuator, which at times prevented the penstock from being lifted – a necessary and frequent operation. There was limited safe access to the penstock, which often failed, and regularly needed a mobile crane to be called out to site to carry out the recovery operation. Thames Water contacted Bramley Engineering to design and install a dedicated rescue lifting solution, supported by upgraded access steelwork for safer, more efficient operation.

Engineering Challenges

Designing a rescue gantry and access upgrade for a live sewage treatment site meant working within tight physical and operational constraints. The solution needed to be structurally robust, fully compliant, and integrated precisely with existing assets, without limiting day-to-day access or future maintenance.

The engineering brief came with some site constraints:

Restricted space: Limited working room and existing equipment meant a ground-supported structure was not practical.
Removable lid and roof: The chamber lid and roof had to remain removable, so all new steelwork was designed to work around this requirement.
Precision interfaces: New components had to align accurately with existing steelwork, bolt hole positions and handrail lines to ensure a safe, seamless fit.
Live-site controls: The project required careful coordination of permits, lift plans, documentation and access restrictions to complete the work safely on a live sewage treatment site.

The Solution

Step 1: Work out a reliable rescue lift method

Because the hydraulic actuator could not be relied on as the only lifting mechanism, we decided the best solution would be a dedicated rescue approach: a monorail gantry with chain block hoists to lift the weir penstock safely whenever required. This gave the Thames Water team a consistent, practical method that can be used at any time.

Step 2: Designed around obstructions

The design had to solve two clear constraints. First, space was limited and the area already had existing fixtures to work around, so a ground-supported structure would have created new obstructions at floor level. The most efficient way to improve access while keeping the footprint minimal was to extend the existing stairs and access walkway.

Second, the storm chamber lid and roof still needed to remain removable for ongoing maintenance, so we could not introduce steelwork that would block or restrict removal. To preserve that access, we affixed the rescue gantry on the side walls of the storm chamber, providing a secure lifting solution while keeping the lid clear when it needs to be lifted out.

Step 3: Survey, 3D CAD design and verification

Because the new steelwork had to interface precisely with existing steelwork, bolt holes and handrail lines, we carried out detailed preparation and testing to get it right first time and verify performance before handover.

Pre-site survey and 3D scanning
Stress analysis to validate loads, reactions and deflection prior to manufacture
Installation planning around site regulations, permits and controls

Step 4: Build a removable access solution over the chamber

the new chain blocks and lifting gantry needed to be accessible but the storm chamber lid still needed to be removable for ongoing maintenance, any new steelwork had to be designed around these requirements. Rather than installing a fixed platform that would restrict storm chamber lid removal, we engineered a removable bridge that spans the lid and provides a safe, stable crossing point during day-to-day operation.

Fabricated in-house, the bridge was designed with integrated lifting eyes so it can be lifted out in a controlled way whenever the lid needs to be removed. With a tare weight of 560 kg, the lifting points and handling method were built into the design from the outset, supporting safer removals and reinstalls, and helping to maintain access without compromising future serviceability.

Step 5: Manufacture, delivery and installation

With the design finalised, we manufactured the gantry and access steelwork in-house to maintain full control over quality, fit and installation standards. Components were then delivered to site ready for a controlled install by Bramley Engineering. Installation was planned around permits and live-site access restrictions, to minimise disruption and ensure a smooth handover.

Step 6: LOLER testing, proof load testing, and pull-out testing

Following installation, we completed a full LOLER test of the finished structure to confirm the gantry and lifting system was safe, compliant and suitable for long-term use. As part of this, we completed proof load testing to confirm the gantry and lifting arrangement performed as intended, and pull-out testing to verify the integrity of the fixings into the existing structure.

As part of handover we issued the relevant certification, valid for the next 12 months, along with the supporting documentation to aid ongoing inspection planning and compliance.

Key Suppliers

This project was delivered with support from trusted UK suppliers, helping us maintain quality, traceability and reliable lead times throughout design, manufacture and installation.

Chain blocks: William Hackett supplied the chain block hoists used as part of the rescue lifting system, providing the dependable lifting performance required.

Steel: AJN Steel Stock supplied the primary steel for the gantry and access steelwork. Using a consistent, reliable steel supplier supported build quality, material traceability and efficient fabrication planning.

Profile plates: HBH Laser produced the profile plates for the project, ensuring clean interfaces where the new steelwork had to align precisely with existing structures.

The Results

24/7 access to the penstock for operation and maintenance
A reliable rescue lift method when the actuator fails, improving resilience on a known recurring issue
Reduced need for mobile crane call-outs, lowering cost and disruption
Faster recovery from faults, helping to reduce downtime and support efficient operation across the inlet channel and storm collection system
The removable bridge provides a safe crossing point, while still allowing controlled removal whenever the chamber needs to be opened for maintenance.

Conclusion

This project demonstrates Bramley Engineering’s ability to deliver practical, compliant lifting and access solutions in complex live-site environments. By working closely throughout the project, combining their operational knowledge with our engineering expertise, we were able to agree the most effective approach for the site. The result is a rescue gantry and access upgrade that improves safety and efficiency without compromising the site’s original design. Critical removable elements, including the storm chamber lid and roof, remain fully accessible for routine servicing, supported by carefully planned interfaces and purpose-designed removable components. The Thames Water sewage treatment works now has a reliable method to rescue and operate the weir penstock, reduce downtime, and avoid unnecessary mobile crane call-outs.

Let’s collaborate on your next lifting solution

When client insight and engineering experience work together, you get a solution that fits the site first time. We can survey, design, fabricate and install a compliant lifting system that suits your constraints and operational needs.

Email: enquiries@bramleyengineering.co.uk

Phone: 01525 375225

How Overhead Cranes Improve Workplace Efficiency

Graham Bramley — Tue, 09 Dec 2025 04:56:26 +0000

Overhead cranes have become a tool relied upon in industries where heavy lifting and precise material handling are required, such as manufacturing, construction, warehousing, or engineering. These cranes provide a safer and more efficient solution to streamline operations and boost productivity across industries. Many businesses that previously functioned using manual handling, forklifts, or pump trucks for lifting operations face challenges like congestion, safety risks, and inefficient material flow. To overcome these obstacles, they are now adopting overhead crane systems, which help optimise operations and improve overall efficiency with enhanced capabilities and space utilisation. Find out exactly how overhead cranes improve workplace efficiency.

What is an Overhead Crane?
Replacing Manual Handling and Forklifts with Overhead Cranes
What are the advantages of overhead cranes?
Energy Efficiency: Why Overhead Cranes Outperform Multiple Machines
What’s the Best Overhead Crane?
The Importance of Choosing a Trusted Overhead Crane Manufacturer

What is an Overhead Crane?

An overhead crane is a robust lifting machine system designed to move heavy loads with precision. These cranes operate on elevated runways and are widely used in manufacturing, engineering, warehousing, construction, and other material handling and lifting industries.

Key components of an overhead crane include:

Bridge: The main structure that spans across the workspace.
Hoist: The lifting mechanism that raises and lowers loads.
Trolley: Moves the hoist along the bridge.
Runways: Fixed rails that support the bridge’s movement.
Controls: Can be manual, pendant-operated, or radio-controlled for precise handling.

Replacing Manual Handling and Forklifts with Overhead Cranes

Forklifts, pump trucks, and manual handling for material movement often lead to operational inefficiencies, accidents, and delays. Forklifts, for instance, are prone to collisions, causing damage to goods and equipment, worker injuries and even lawsuits. Manual handling, on the other hand, not only slows down productivity but also increases the risk of injuries with handling, lifting or carrying responsible for 17% of all non-fatal workplace accidents reported under RIDDOR according to HSE.

By introducing an overhead crane, businesses can eliminate these inefficiencies and improve safety. Overhead cranes move loads smoothly and precisely, reducing the risks associated with forklifts and manual handling. They also free up floor space, allowing workers to operate in a safer, more organised environment.

What are the advantages of overhead cranes?

One of the biggest advantages of overhead cranes is their ability to optimise factory workflow. In industries such as automotive manufacturing, steel fabrication, and logistics, maintaining a smooth and efficient production flow improves output and allows businesses to meet deadlines consistently.

Different overhead cranes support different operational layouts, including linear and U-shaped production processes to enable the movement of materials without interrupting production lines. With a well-integrated overhead crane system, businesses can optimise space and create a more structured working environment that promotes production.

Enhanced Lifting Capabilities for Complex Environments

Overhead cranes lift loads above obstacles such as machinery, workstations, and storage racks, allowing movement even in crowded spaces.
Unlike forklifts and pallet jacks, which require dedicated pathways, overhead cranes operate from above, freeing up valuable ground space for workstations, storage, or an increase in production lines.
Customisable lifting solutions, including single-girder, double-girder, gantry, and jib cranes, can be tailor-made to function for specific operational needs. Get in touch to find out more about Bespoke Crane Manufacturing.

Increasing Productivity and Work Output

Automating and streamlining the lifting process allows workers to complete tasks more quickly and with greater precision.
Reduces manual handling efforts, minimising worker fatigue and preventing injuries.
Overhead cranes replace slow loading and unloading processes in logistics and warehousing, reducing overall turnaround times.
In manufacturing, cranes enable faster movement of heavy components along production lines to speed up assembly.
Consistently higher productivity gives businesses improved profitability and can lead to significant growth.

Improving Workplace Safety and Reducing Accidents

Provides a safer alternative to forklifts, minimising risks associated with improper operating and workplace collisions.
Cranes are equipped with precision controls, load monitoring, and remote operation features to enhance lifting accuracy and reduce human error.
Prevents dropped loads, sudden shifts, and improper load handling, reducing the risk of accidents and equipment damage.
Having fewer workplace accidents prevents downtime, lowers compensation claims, and improves employee well-being, morale and retention.

Energy Efficiency: Why Overhead Cranes Outperform Multiple Machines

Investing in an overhead crane instead of relying on multiple ground-based lifting machines also saves energy. Businesses across industries, including manufacturing, construction, rail, and warehousing, are increasingly turning to overhead cranes to streamline lifting operations while reducing their environmental impact to support our planet.

How Overhead Cranes Improve Energy Efficiency

One Crane, Lower Energy Demand
- Running multiple machines consumes far more energy than a single overhead crane. Forklifts, pallet jacks, and mobile lifting equipment require multiple power sources, leading to higher fuel or electricity consumption.
- Overhead cranes are powered by high-efficiency motors and variable frequency drives (VFDs) that deliver controlled and consistent energy use.
Crane Regenerative Braking Technology
- Some modern overhead cranes include regenerative braking, which converts excess kinetic energy into reusable electrical power.
Eliminates Idling and Standby Energy Waste
- Forklifts consume energy even when stationary, whether idling between tasks or waiting for operators.
- Overhead cranes operate only when needed removing excessive standby losses.

By choosing an overhead crane manufacturer that prioritises energy efficiency, businesses can cut operating costs and improve sustainability and their environmental impact.

What’s the Best Overhead Crane?

Choosing the best overhead crane depends on several factors, including load capacity, facility layout, and specific application needs. Different types of overhead cranes offer unique advantages:

Bridge Cranes – Ideal for factories and warehouses requiring high-capacity lifting. Available in single or double girder configurations.
Gantry Cranes – Best for outdoor applications or spaces where a permanent crane structure isn’t feasible.
Monorail Cranes – Suitable for production lines requiring linear movement.
Jib Cranes – Perfect for localised lifting tasks, available in wall-mounted or freestanding options.
Workstation Cranes – Designed for smaller, repetitive lifting tasks with ergonomic efficiency.

We can discuss your needs and operations to establish which type of crane will be most suitable and we also offer bespoke designs tailored to your business. To determine the best crane for your operation, we’ll consider:

Load Capacity: What is the maximum weight the crane needs to lift?
Operational Frequency: How often will the crane be used?
Work Environment: Are there space constraints or facility obstructions?
Control System: Do you need manual, pendant, or remote control operation?
Installation & Maintenance: Does your facility support fixed or mobile systems?

Once assessed, we can select or design an overhead crane that enhances efficiency, improves safety, and maximises return on investment. Get in touch for a consultation to find the best fit for your needs.

The Importance of Choosing a Trusted Overhead Crane Manufacturer

Selecting the right overhead crane manufacturer is also important. One size doesn’t ‘fit all’ when it comes to using cranes to improve efficiency. A reputable manufacturer like Bramley Engineering will provide bespoke crane systems designed to meet specific industry requirements and get the most from your money. From consultation and design to installation and maintenance, our team ensures that you receive high-quality solutions tailored to your operational needs.

Our overhead cranes are built to withstand demanding industrial environments, offering durability, reliability, and precision. We understand that efficiency is not just about lifting loads – it’s about integrating the right technology to perform better across the board.

Why Businesses Should Invest in Overhead Cranes

With the right overhead crane in place, businesses can achieve higher efficiency, increased safety, and a significant return on investment by reaping the advantages cranes offer, including:

Faster Production Cycles – Streamlines material movement and reduces processing times.
Cost Savings – Minimises the need for manual labour and forklift-related expenses.
Improved Workplace Safety – Reduces accident risks and enhances compliance with lifting regulations.
Optimised Space Utilisation – Frees up factory floor space for improved operational efficiency.
Customisable Solutions – Tailored crane systems designed for specific industrial applications.

Improve Your Workplace Efficiency with a Bramley Engineering Overhead Crane

Overhead cranes are revolutionising workplace efficiency across various industries, from manufacturing and warehousing to construction and engineering. By replacing outdated lifting methods, enhancing safety, and optimising lifting and loading processes, they provide businesses with the tools needed to remain competitive and productive.

Here at Bramley Engineering, we specialise in designing and manufacturing high-performance overhead cranes that meet the evolving needs of industrial operations. If you’re looking to upgrade your lifting solutions, our team is here to help. Contact us to find out how our bespoke overhead cranes can transform your workplace, or request a free design and quote today.

Case Study: Telescopic Runway Beam for a Global Manufacturer

Graham Bramley — Tue, 25 Nov 2025 13:09:18 +0000

A leading building materials and construction solutions manufacturer operates specialist machinery at one of its UK sites, producing paving bricks. As part of the process, heavy mould components must be lifted and accurately positioned within the machine, a frequent operation of the manufacturing process. Historically, this task relied on an older articulated jib crane; whilst the operation was previously manageable, it was clear that the ageing equipment could certainly be improved from an efficiency and safety perspective. When the manufacturer instructed Bramley Engineering, a safer, more efficient solution was found.

Project Summary

Client: 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

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.

The client needed a solution that removed these issues while integrating neatly into the existing workspace. Safety, reliability, and precise positioning were essential.

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 the clients 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 the 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.

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, the client 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

Safety Training in Crane Operation & Maintenance

Graham Bramley — Tue, 18 Nov 2025 04:55:55 +0000

Crane operation involves significant risk, which makes safety training an essential aspect for businesses relying on lifting equipment. Whether in construction, manufacturing, or specialised industries, comprehensive training ensures operators and maintenance teams can handle equipment safely and efficiently. As bespoke crane manufacturers, we’re highlighting the importance of safety training in crane operations, covering LOLER regulations, tailored training for custom crane usage, and ongoing maintenance requirements.

Why Safety Training is Essential for Crane Operators
Training for LOLER Compliance
Maintenance Training
Training for Operating Bespoke Cranes

Why Safety Training is Essential for Crane Operators

Crane operators play a central role in lifting operations, and without proper training, both employees and equipment are at risk of harm or damage. A well-trained operator can identify hazards, prevent mistakes, execute precise movements, and understand the load limits of lifting equipment. Training helps operators:

Minimise accidents: Properly trained operators reduce the amount of human error that can occur during operation, which is one of the main causes of crane-related accidents.
Improve efficiency: Knowledgeable operators can carry out lifts safely and quickly, minimising downtime during projects.
Ensure regulatory compliance: For businesses to comply with UK laws such as the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER), it is essential that crane operators are trained to operate their lifting equipment safely.

At Bramley Engineering, we prioritise safety in every aspect of crane operation. Alongside our bespoke crane design services, we provide operational training and LOLER inspection services to ensure your workforce can use custom equipment effectively.

Training for LOLER Compliance

LOLER inspections are a legal requirement for all lifting equipment used in any work environment. Part of staying compliant with LOLER requirements is ensuring that your staff is adequately trained to operate and maintain lifting equipment with minimal risks. Some key aspects of LOLER-compliant training include:

Understanding load limits: Operators must know the maximum safe working loads (SWL) of the crane and lifting accessories.
Safe use of lifting accessories: Training covers how to safely attach and detach slings, chains, eyebolts, and other accessories used during lifting operations.
Inspection knowledge: Operators should be familiar with the inspection process and be able to recognise signs of wear and tear in lifting equipment.

Read our guide on LOLER inspections to find out more.

Maintenance Training

In addition to training operators, ensuring that maintenance staff are well-trained is essential to protect staff from harm and ensure equipment’s longevity, minimising wear and tear.

Trained maintenance staff should be able to effectively:

Conduct routine inspections: Regular checks help identify potential issues before they lead to costly repairs or accidents.
Recognise wear and tear: Signs of deterioration can appear on both machines and accessories like chains, slings, and pulleys. All will need to be inspected for signs of degradation regularly.
Schedule timely servicing: Knowing when to service cranes according to LOLER standards helps avoid equipment failure. These regulations apply to both generic cranes and custom cranes & equipment.

Training for Operating Bespoke Cranes

Bespoke cranes are custom-made to fit the unique requirements of different industries, and operating these cranes often requires specific training even for versed crane operators. Whether it’s a custom overhead crane or a gantry crane for specialised environments, operators must be trained to handle the unique features of the equipment.

Tailored instruction: Each bespoke crane will have different controls, safety features, and load capabilities that need to be understood by the operator.
Unique operational environments: Bespoke cranes are often installed in industries with unusual operational environments where training is essential to operate safely, such as in confined spaces or hazardous areas.

With our bespoke crane solutions, we provide advice on operator training to make sure that your team is fully equipped to operate your custom crane safely and efficiently. By providing your team with the right training, you not only ensure regulatory compliance with LOLER but also improve operational efficiency and safety, protecting both your team and business.

At Bramley Engineering, we offer bespoke crane design, LOLER inspection services, and comprehensive guidance on safety training. Get a free bespoke crane design & quote today.

How Often Should You Pull Out Test Lifting Anchors?

Graham Bramley — Tue, 28 Oct 2025 04:55:16 +0000

In any construction or build, the reliability of anchor points is essential for both general safety and legal compliance. A pull out test verifies the strength of anchor bolts, fastenings, and fixings, preventing failures that could lead to serious accidents.

So, how often should pull out testing be performed? While an annual test could be a standard benchmark, the real answer depends on several factors which we will cover in this blog, including industry regulations, environmental conditions, and the type of operations involved.

What Is a Pull Out Test?
What Is Pull Out Testing Used For?
How Often Should You Perform Pull Out Testing on Lifting Anchors?

What Is a Pull Out Test?

A pull out test is a method used to assess the strength and reliability of anchor points, bolts, and fixings. Anchor points and fixings are commonly used for securing ropes and fall arrest systems in lifting industries, so the strength and stability of each anchor are integral to maintaining safety, complying with regulations, and preventing accidents. Pull out testing ensures that anchor points can withstand the forces used in operation without damage or failure.

What Are Anchor Points in Lifting Operations?

An anchor point is a secure, fixed location designed to support the attachment of lifting equipment or loads (including people), such as crane and hoist operations. These points help distribute forces more effectively when lifted.

There are different types of anchor points depending on the lifting requirements:

Structural Anchors – Fixed points integrated into buildings or steel structures, designed to handle specific load capacities.
Anchor Loops or Rings – Purpose-built attachment points installed for hoisting and lifting tasks.
Temporary Anchors – Portable or removable anchors used when a permanent fixed point is unavailable.

What Is Pull Out Testing Used For?

The test is used primarily to check for wear, material fatigue, or defects in anchor points. Most commonly, pull out testing is used for:

Lifting equipment – Ensure anchor bolts and fastenings can handle operational loads.
Construction and structural support – Test the integrity of fixings in buildings, bridges, and other structures.
Fall protection systems – Verify that safety harness anchor points are secure to protect staff working at height.

By simulating real-world forces with a pull tester or tensile tester, a pull out test helps prevent failures that could lead to structural damage, dropped loads, or workplace injuries.

How Is a Pull Out Test Done?

Pull out testing is conducted using specialised testing devices called tensile testers. One of the best tensile testers is a Hydrajaws pull tester (we use the Hydrajaws M2050), which applies a measured force to an anchor or fixing to assess its load capacity. The results indicate whether the fixing meets anchor bolt pull out test standards, such as BS 8539, and operational load requirements to ensure it can perform safely.

How Often Should You Perform Pull Out Testing on Lifting Anchors?

The frequency of pull out testing depends on industry-specific regulations, environmental exposure, and how often the lifting anchors are used. As a general guide, below are the key factors influencing testing intervals. However, in any case, we recommend regular testing to ensure safety, compliance, and equipment longevity as this minimises the risk of damage that could cause load drops, injuries, and costly repairs.

Routine Testing

As a general rule, lifting anchors should undergo pull out testing at least once a year as part of scheduled safety inspections. Annual testing ensures that anchors maintain their load-bearing capacity and have not been compromised due to wear and tear. An annual routine test will also help your business comply with industry regulations like LOLER (Lifting Operations and Lifting Equipment Regulations 1998) and insurance requirements.

Heavy-Use Environments

In industries where lifting anchors are used frequently, such as construction, manufacturing, and offshore operations, testing intervals should ideally be shortened to every six months.

High-load operations: If anchors are consistently working with maximum or near-maximum loads, they experience greater stress and should be tested more often.
Harsh working conditions: Exposure to corrosive environments, like marine locations, chemical plants, or extreme temperatures, can weaken anchor bolts over time. More regular testing helps spot early signs of damage and material degradation.

Post-Installation Testing

Any newly installed or relocated anchor should undergo an initial pull out test before being put into service. A test should also be carried out after an anchor has been repaired or re-installed for any reason.

Regulatory Compliance

Several industry standards and regulations dictate the frequency of pull out testing:

LOLER – Requires lifting equipment to be examined at specified intervals to ensure safety.
BS 8539 – Governs the installation and testing of anchors used in construction, specifying that anchors must be tested after installation and regularly thereafter.
PUWER (Provision and Use of Work Equipment Regulations 1998) – Ensures work equipment is maintained in a safe condition and regularly inspected.

Failure to comply with these regulations can result in fines, equipment failure, and workplace accidents. Testing ensures that lifting anchors remain legally compliant and protects your business and insurance policy.

After an Incident or Structural Change

Lifting anchors require additional tests in some cases:

Excessive load or impact – If an anchor has experienced an overload situation or accidental force beyond its rated capacity, it may have weakened structurally.
Environmental damage – Rust, chemical exposure, or structural deterioration can reduce an anchor’s effectiveness.
Modifications or relocation – If the surrounding structure or anchor itself has been altered, moved, or repaired, its strength and integrity will need to be re-tested.

While annual testing is a basic recommendation, factors such as heavy use, environmental exposure, and regulatory requirements may be cause for more frequent checks. By following a structured testing schedule with a reputable pull testing service, businesses can prevent expensive failures, comply with safety standards, and ensure the longevity of their lifting equipment.

Book a Pull Out Test with Bramley Engineering

At Bramley Engineering, we specialise in pull out testing across industries including lifting, construction, and engineering. We provide easy, convenient services backed by industry-leading standards.

Contact us today to schedule your test and ensure your fixings meet the highest safety requirements. Call us on 01525 375225 or drop us an email at enquiries@bramleyengineering.co.uk.

5 Most Common Challenges in Overhead Crane Manufacturing

Graham Bramley — Tue, 07 Oct 2025 05:00:23 +0000

Overhead crane manufacturing is a complex process requiring precision, safety considerations, and innovative engineering. At Bramley Engineering, we specialise in bespoke crane design and build solutions, overcoming challenges that many manufacturers struggle with. Here’s how we navigate the 5 most common obstacles in crane design and manufacturing, which are:

Structural Integrity & Wind Loading – Outdoor cranes must withstand wind forces; poorly designed gantry columns can increase material costs.
Hazard Risk & Prevention – Risks include finger trapping, untrained user access, environmental exposure (dust, rain, food-grade conditions).
Delivery & Installation Problems – Large cranes can be difficult to transport and assemble, sometimes reducing load capacity.
Compliance with Safety Regulations – Meeting LOLER and industry safety standards is essential to avoid fines and accidents.
Cost-Effective, Sustainable Design – Balancing affordability with durability and efficiency while maintaining structural resilience.

1. Structural Integrity and Wind Loading

When designing an overhead crane or gantry crane, structural integrity is crucial. Outdoor overhead gantry cranes face significant challenges from wind loading, which can impact stability and efficiency. Many manufacturers struggle or fail to address this adequately, leading to compromised safety and often unnecessarily increased material costs.

Our Solution: Bramley Engineering designs gantry columns that are virtually see-through, significantly reducing wind resistance. We’re known for this unique design that enhances the column’s strength while allowing for more cost-effective steel without sacrificing durability. This ensures your outdoor cranes remain stable and efficient in high-wind environments.

2. Hazard Prevention in Crane Design

Overhead crane designs must proactively mitigate potential hazards. The most common hazards fall into two categories:

People Hazards

Finger trapping and entanglement – Poorly designed cranes can pose serious risks of workplace injuries to operators.
Untrained user risks – Some cranes are accessible to untrained personnel, increasing the likelihood of accidents if they can access the controls.

Our Solution: We incorporate control enclosures to lock crane control mechanisms and pendants away from untrained users, ensuring only authorised personnel are able to operate the equipment.

Environmental Hazards

Wind and rain exposure – Outdoor cranes must withstand varying weather conditions. A common problem with overhead travelling cranes is the travelling beam being taken by the wind and colliding with the end stops of the gantry.
Food-grade environments – Standard lubricants are unsuitable for food manufacturing plants.
Dust accumulation – Dust can cause mechanical wear over time.

Our Solution:

Aside from using high-quality, durable materials, we include bespoke features to enhance safety and efficiency, ensuring your crane design is fit for purpose. These could include:

Use of food-grade oils for clean environments like food manufacturing and utility work.
Integrated brushes on moving parts enable self-cleaning by dusting the crane as it operates.
Wind-lock mechanisms to prevent jibs from uncontrolled slewing in windy conditions, minimising damage.
Parking brakes on overhead travelling cranes to prevent beams from shifting due to wind, to avoid collisions with end stops.

3. Delivery and Installation Challenges

Transporting and installing large cranes like gantry cranes and bridge cranes can be complex. The size and weight of cranes make delivery and installation particularly challenging, especially when access to the installation site is restricted. In some cases, cranes need to be transported in smaller pieces and assembled on-site, which can affect load capacity.

Our Solution: We design modular cranes that can be broken down into smaller parts without compromising their safe working load (SWL). If modifications do impact load capacity, we’ll conduct redesigns to ensure the crane meets SWL requirements while providing an easier installation.

4. Compliance with Safety Regulations

From EOT crane manufacturing to ceiling cranes, we know all lifting equipment must completely comply with LOLER (Lifting Operations and Lifting Equipment Regulations) and in some cases PUWER (Provision and Use of Work Equipment Regulations 1998) guidelines. Non-compliance can lead to severe fines, staff injuries and operational shutdowns.

Our Solution: Our designers are highly trained to provide fully compliant designs that exceed industry safety standards. We can integrate advanced control systems and features such as limit switches, electronic sensors to enforce no-go zones, automated stop functions, and protective enclosures to safeguard both personnel and equipment.

And it doesn’t stop there. We can also conduct ongoing LOLER inspection services with our own qualified LOLER inspectors to keep your cranes fully operational and legally compliant.

5. Cost-Effective, Sustainable Design

Balancing affordability with performance and durability is a key challenge for crane manufacturing companies. Cheaper materials may lower upfront costs but can dramatically compromise safety and longevity, often costing more in the long run through repairs and replacements.

Our Solution: We design with strategy, making careful choices on features like wind-resistant gantry columns and modular components to maintain affordability without sacrificing quality. Our approach reduces steel costs while enhancing structural resilience, offering you the best value crane for your needs.

Why Choose Bramley Engineering to Design and Build Your Crane?

With over 40 years of expertise in overhead crane manufacturing, we solve complex design, build and installation challenges that other companies struggle with. We offer more than just a crane design and build, with Bramley Engineering you’ll receive:

Bespoke Crane Solutions: Every project is custom-engineered to meet your specific operational requirements.
Expert Compliance & Safety Assurance: Our cranes are designed to meet LOLER and all industry safety standards.
End-to-End Service: From initial design to installation and ongoing maintenance, we provide a seamless, hassle-free experience.

Get a Free Crane Design Consultation Today!

Looking for a reliable, bespoke overhead crane? Contact Bramley Engineering for a free design and quote. Let’s build a more efficient lifting solution for your business.

For more information, get in touch! Email us at enquiries@bramleyengineering.co.uk or give us a call on 01525 375225 and we’ll be happy to help.

Case Study: Bespoke Overhead Travelling Crane for Oxford Flow

Graham Bramley — Mon, 22 Sep 2025 16:42:01 +0000

Oxford Flow, a global leader in valve and regulator innovation, recently relocated to a new facility in Witney, Oxfordshire. To support their expansion, they required a future-ready lifting system for larger, heavier components. Bramley Engineering was commissioned to deliver a bespoke overhead crane and runway that meets current demands while providing the capacity and efficiency needed for long-term growth.

Project Summary

Location: Witney, Oxfordshire
Objective: Future-proof lifting capability for larger assemblies, higher throughput, and safer handling
Solution: Bespoke overhead travelling crane beam with purpose-designed runway gantry, fully modelled from a 3D cloud-point survey
Outcome: Higher productivity, safer operations, and headroom for growth in line with Oxford Flow’s manufacturing roadmap

The Challenge

Prior to the upgrade, lifting relied on smaller loads and mobile gantries that were slow and cumbersome. Oxford Flow wanted to future-proof the new factory so larger components and heavier assemblies could be handled safely and repeatably, without bottlenecks. The brief called for a brand-new overhead system in the Witney facility rather than an upgrade.

Our Engineering Response

To meet Oxford Flow’s operational needs, we applied a rigorous, end-to-end engineering approach. Our focus was on creating a solution that balanced precision, safety, and cost-effectiveness, while integrating seamlessly into the existing facility.

Survey and design: We completed a full 3D scan of the factory to generate a precise cloud-point model. This allowed us to check clearances, optimise hook approaches, validate headroom against the Height of Lift, and minimise steel tonnage while maintaining stiffness and serviceability. We then produced construction-issue drawings and iterated the design to align with Oxford Flow’s budget and workflow.

Runway and support: We designed and built a floor-fixed supporting gantry on both sides of the bay, integrated with the building architecture. The solution blends with the facility visually while delivering the required long-travel runway performance. The crane itself spans 24 metres across the bay and travels 30 metres end-to-end, giving Oxford Flow full coverage of their work area.

Hoist and duty input: We consulted STAHL CraneSystems, part of Columbus McKinnon, for the hoist specification and duty classification input in line with FEM and ISO industry standards. This ensured that the crane’s lifting and travel motions were matched to Oxford Flow’s expected usage and workload.

Manufacture and Design

Delivering a crane system of this scale required careful coordination from design through to commissioning. Bramley Engineering took responsibility for the supporting steelwork and crane beam, while STAHL CraneSystems supplied the hoist crane kit. Together, these elements formed a complete solution tailored to Oxford Flow’s new facility.

Supporting Steelwork: Bramley Engineering fabricated and installed the gantry steelwork to carry the overhead crane system. The structure was floor-fixed for stability and carefully designed to integrate with Oxford Flow’s new facility. By optimising the design, we reduced unnecessary steel while maintaining strength and reliability.

Beam: We manufactured the crane beam and ensured its precise fit with the supporting steelwork. The fabrication process delivered the required stiffness and accuracy so the beam could operate under heavy duty conditions as part of the wider system.

Hoist: The hoist crane kit (SH wire rope hoist) from STAHL CraneSystems was selected for its 5,000 kg Safe Working Load, 6 m Height of Lift, and classification in line with industry standards, ensuring it is suited to the workload and usage cycle of the new Oxford Flow facility.

Installation and Testing

The crane beam was fabricated by Bramley Engineering in Northamptonshire and then transported Oxford Flow’s factory in Witney under a police escort, arranged with Northamptonshire Police due to the beam length and route constraints. Installation proceeded smoothly and to programme, and commissioning included static and dynamic load testing.

We proof-loaded to approximately 125% of SWL using calibrated test weights of 6.29 tonnes and recorded a bridge deflection of 27 mm, within the 32 mm limit set at design stage. This verified performance and serviceability prior to handover.

Compliance and Good Practice

The system and supporting runway were designed and verified against the applicable crane and structural standards, and the project was delivered under the UK regulatory framework for lifting equipment:

Crane standard: BS EN 15011 for bridge and gantry cranes, covering hazards, verification, and safety requirements.
Runway and supports: Eurocode 3, BS EN 1993-6 for crane-supporting structures, with actions from cranes taken in accordance with Eurocode 1, EN 1991-3.
Regulatory context: LOLER 1998 and the BS 7121 Code of Practice for the safe use, inspection, and thorough examination of bridge and gantry cranes.

Results and Benefits

Capacity and reach: 5,000 kg SWL across a 24 m bridge span with a 30 m long-travel runway provides the envelope needed for larger assemblies and fixtures.
Productivity: Faster, repeatable handling replaces time-consuming mobile gantry operations and reduces changeover delays.
Safety and ergonomics: Controlled lifts within a defined handling envelope reduce manual handling and improve operator safety.
Scalability: The runway geometry and duty alignment support Oxford Flow’s growth in valves and regulators for larger product sizes.
Client response: Oxford Flow reported they are very happy with the outcome and the way the system supports their expansion plans.

“Having worked with Graham and Bramley Engineering previously, I knew just who to call when we required an overhead crane for our new production facility. Their services throughout were excellent, from the initial site visit through to install and commissioning; and their capability to 3D scan the area and provide an accurate model, gave us peace of mind before the installation began. I’d highly recommend Bramley Engineering for all your lifting requirements.” — Jonathan Yaxley, Project Manager, Oxford Flow

Technical Data

SWL (Safe Working Load): 5,000 kg
Height of Lift (HOL): 6 m
Bridge Span: 24 m
Runway Length (LT travel): 30 m

Why Bramley Engineering

From cloud-point scanning and constructible detailing to proof loading and handover, our team delivers end-to-end lifting solutions that integrate with your building and your process. The Oxford Flow crane beam joins our portfolio of bespoke installations for complex environments, alongside recent projects such as the FCC Recycling slewing jib crane.

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

What Is A Pull Out Test? | Our Testing Procedure & Method

Graham Bramley — Tue, 16 Sep 2025 05:00:40 +0000

A pull out test is a method used to check whether anchors, bolts, fixings, and safety points can safely withstand the loads they will face during lifting, fall protection, or structural operations. The test works by attaching a calibrated device to the fixing and gradually applying force until it reaches either a specified safe load or the point of failure. This process measures the true holding capacity of the component. The lifting industry requires these tests to reduce the risk of catastrophic failure, leading to accidents, equipment damage, and non-compliance with safety regulations.

In this guide, we explore everything you need to know about pull out testing, including its importance, methodology, and compliance with British standards.

What Is a Pull Out Test?
Why Is Pull Out Testing Important?
How Pull Out Testing Works
Our Pull Out Testing Procedure
What Is the British Standard for Pull Out Tests?
Why Choose Bramley Engineering for your Pull Out Tests?

What Is a Pull Out Test?

Pull out testing is widely used in construction, lifting operations, and fall protection systems to ensure that critical components like anchor points and bolts can withstand the forces they will encounter when in use. It’s typically performed before installations to confirm load capacity using a hydraulic pull tester or tensile load tester, which applies a controlled force to the anchor point of fixing and measures capacity.

Pull testing (also called pull-out testing) is usually used prior to installation and can also be destructive if required, meaning it can apply a force until the anchor, fastener, or component fails to determine its ultimate load capacity. This test helps in selecting appropriate fixings for new installations.

Purpose: Determines the maximum force an anchor or fastener can withstand before failure.
Method: Applies a gradual, increasing force until the fixing pulls out, breaks, or the test limit is reached.
Result: Establishes the load capacity and helps identify failure points such as concrete cone failure, pull-out failure, or anchor head failure.

Pull-out testing is typically performed before installations to confirm load capacity, while proof load testing is done regularly to ensure ongoing safety and compliance to pass LOLER inspections and meet British Standards.

Why Is Pull Out Testing Important?

The failure of an anchor point can have catastrophic consequences including dropped loads, damaged equipment and property, or serious injuries. Conducting thorough anchor testing with a pull out test helps prevent these issues, protecting businesses, equipment, and staff. It’s important to pull test for several reasons:

Ensures Structural Integrity – It verifies whether anchors and fixings can withstand the required load without failing.
Compliance with Safety Standards – Industries such as construction, engineering and any lifting operations must meet strict safety regulations, including LOLER (Lifting Operations and Lifting Equipment Regulations) and British Standards.
Prevention of Accidents – Weak or faulty fixings can lead to structural collapses, equipment failures, and serious workplace injuries.
Cost Savings – Identifying weak anchor points before they fail helps to prevent expensive repairs, downtime, and potential fines.

How Pull Out Testing Works

The process of pull out testing involves attaching specialised testing equipment (we use the Hydrajaws m2050) to an anchor or fixing and applying a controlled tensile force. The aim is to determine the maximum load the anchor can withstand before it pulls out or reaches a set threshold. The results help engineers and safety inspectors assess whether the anchor meets the required load-bearing capacity for its intended use.

The key components of a pull out test include:

A hydraulic or mechanical testing device such as a Hydrajaws pull tester
A load gauge to measure applied force
A fixed anchor or sample material
A controlled pulling mechanism or machine to apply force gradually

Our Pull Out Testing Procedure

Knowing how to perform a pull out test is essential for ensuring anchors and fixings meet safety standards. At Bramley Engineering, we follow a clear five-step procedure:

Identify the Test Location – Select the anchor point or fixing to be tested.
Prepare the Equipment – Attach the testing device securely to the fixing.
Apply Load Gradually – Use a hydraulic or mechanical tester to apply a controlled force.
Monitor Load Resistance – Measure the force required for failure or assess if the anchor meets the required standard without pulling out.
Record the Results – Document the load capacity and compare it against safety standards and requirements.

Book your pull out test with us and we’ll take care of each step, scheduled at a time that suits you. With Bramley Engineering, you’ll also benefit from aftercare assistance including repairs, replacements and digital record-keeping. Plus, you can access additional ongoing services such as LOLER tests and proof load testing, all handled and managed by us. Contact us today to find out more.

Understanding Pull Test Scores

The “score” on a pull test refers to the recorded load at which the fixing either holds firm or fails. This is typically measured in kilonewtons (kN) and compared against the required safety threshold. If an anchor meets or exceeds the required load rating, it passes; if it fails prematurely, the anchor point will need to be corrected through reinforcing or replacing the anchor. Don’t worry, we can help with repairs, replacements and reinforcements if you need them.

How Do You Calculate Pull Out Test Results?

Our Hydrajaws pull tester automatically calculates the results of each pull out test and the calculation is based on the force applied and the anchor’s response. The formula for determining the pull out strength is typically:

Pull Out Strength = Load Applied / Surface Area

The results are then checked against the safety standards needed for the application to see if the anchor can be used safely.

What Is the British Standard for Pull Out Tests?

Pull out testing in the UK follows specific British Standards to ensure consistency, accuracy, and reliability. The most relevant standard for anchor testing is BS 8539, which sets out best practices for selecting, installing, and testing anchors in construction and lifting applications.

The standard outlines clear responsibilities for specifiers, manufacturers, installers, and testers, ensuring that only the correct anchors are used and installed according to manufacturer guidelines. Proper procedures must be followed, including correct drilling methods, hole cleaning, and torque application, to ensure accurate test results and full compliance. BS 8539 also requires pull out testing to be carried out on-site using calibrated equipment, with results recorded and compared against required performance criteria.

Why Choose Bramley Engineering for your Pull Out Tests?

With over 40 years of experience in the lifting and engineering industry, we always conduct pull-out testing with accuracy and in full compliance with BS 8539, ensuring that all anchor points, fixings, and structural supports meet the highest safety standards for any lifting operations.

Our industry accreditations including LEEA Full Membership and UVDB, THSP, and ISO 9001 certifications, demonstrate our commitment to industry-leading safety practices. We’re also a fully insured company with Coughlan Business Insurance, and we guarantee safe, reliable, and fully documented pull-out testing services that keep your operations compliant, efficient, and secure.

Whether you need a pull out test for lifting equipment, fall protection systems, or structural anchors, we’re here to help. Get in touch with Bramley Engineering today for reliable pull out testing – call us on 01525 375225 or drop us an email at enquiries@bramleyengineering.co.uk.

Case Study: FCC Bespoke Jib Crane With Structural Steelwork

Graham Bramley — Tue, 29 Jul 2025 09:57:26 +0000

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

Client: FCC Recycling (UK) Ltd, Greatmoor site, Buckinghamshire
Challenge: Replace outdated lifting equipment that could no longer meet operational demands
Solution: Design, fabrication and installation of a new 1500kg SWL slewing bespoke jib crane with structural reinforcement
Key Features: 3D scan and CAD stress analysis, structural steelwork reinforcement, retrofitted motorised slewing mechanism
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:

Safer lifting operations that remove the need for manual handling
A stronger, custom-built support structure to suit the site
A longer reach and higher lifting capacity
Compliance with LOLER and modern H&S standards
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