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STAHL CraneSystems Hoist Supports FCC Recycling’s Bespoke Jib Crane Upgrade
Bramley Engineering, a UK based lifting systems specialist and crane manufacturer, partnered with Columbus McKinnon to deliver a safer, higher capacity lifting solution for FCC Recycling’s Greatmoor facility in Buckinghamshire.
Power and Utilities | Crane Systems | Hoisting & Lifting | by Dibble Digital | 26 Nov 2025
At the heart of the project is a STAHL CraneSystems ST chain hoist which was integrated into Bramley’s custom designed jib crane and structural steelwork. The new system has transformed how FCC handles demanding ash extractor maintenance in a confined and complex space.
Project Summary
- Client: FCC Recycling (UK) Ltd, Greatmoor Energy from Waste facility, Buckinghamshire
- Location: Greatmoor, Buckinghamshire, UK
- Integrator: Bramley Engineering
- Objective: Replace an ageing jib crane and reduce manual handling risks during ash extractor maintenance
- Solution: Bespoke 1,500 kg SWL slewing jib crane with structural reinforcement, equipped with a STAHL CraneSystems ST chain hoist and powered slewing controls
- Outcome: Safer, compliant and more efficient lifting operations fully integrated into FCC’s maintenance regime
Background
FCC Recycling’s ash extractor requires regular maintenance, involving the removal and repositioning of heavy components for inspection and repair. The existing jib crane on site had limited capacity and reach, and its age meant it was no longer suited to the increasing demands of the maintenance operation.
As the equipment became harder to handle, manual lifting and improvised workarounds began to replace proper mechanical handling. This introduced safety risks, created inefficiencies and did not meet FCC’s stringent health and safety requirements.
FCC appointed Bramley Engineering to design a modern lifting solution that would:
- Safely handle loads up to 1,500 kg
- Operate within a restricted plant layout around the ash extractor
- Integrate with the existing building structure while meeting compliance expectations
To achieve the required performance and dependability, Bramley selected a STAHL CraneSystems ST chain hoist from Columbus McKinnon as the central lifting component.
Engineering the Solution
The project was built around a bespoke slewing jib crane, supported by additional structural steelwork to safely manage the increased loading.
Bramley Engineering carried out a comprehensive 3D scan of the installation area, capturing the ash extractor, walkways and existing building steelwork. This enabled detailed modelling of the crane geometry, clearance checks and stress analysis before fabrication began.
The analysis confirmed that the original structure could not support the new crane under full load. To resolve this, Bramley designed and installed new supporting steelwork to accommodate the 1,500 kg SWL jib crane. The design was then independently reviewed by McFarland Consulting to validate structural integrity and compliance.
Within this engineered framework, the STAHL CraneSystems ST chain hoist was selected for:
- Reliable performance under repetitive maintenance loads
- Smooth and precise lifting close to process equipment
- Compatibility with powered slewing and radio control within restricted areas
Precision Installation and Motorised Slewing
After installing the jib crane and structural steelwork, commissioning revealed an additional operational challenge. Due to tight access around the ash extractor, manual slewing was not practical.
To address this, Bramley Engineering implemented a motorised slewing system controlled via radio. This allowed operators to position the jib safely and accurately from a clear vantage point, away from confined areas.
Additional measures included:
- Limit switches fitted to define the safe slewing area
- Overtravel protection to prevent the jib entering the structure
- Neat routing of cables and control equipment for ease of maintenance
The result is a crane that can be maneuvered smoothly within tight boundaries using powered operation rather than manual force.
Safety and Compliance
The new lifting system supports FCC’s obligations under:
- LOLER regulations for lifting equipment
- UK health and safety guidance surrounding manual handling and safe access
By replacing manual handling and an ageing crane with a modern, structurally validated system built around a proven STAHL CraneSystems ST chain hoist, FCC now has a safe and compliant long term maintenance solution.
Results
Key Technical Data:
- Safe Working Load: 1,500 kg
- Crane Type: Slewing jib crane with structural reinforcement
- Hoist: STAHL CraneSystems ST chain hoist
- Control: Radio controlled motorised slewing with limit switches
Key Benefits for FCC:
- Reduced manual handling and reduced risk for maintenance teams
- A purpose designed steel support structure suited to the site
- Increased reach and capacity for ash extractor maintenance
- Compliance with LOLER and current safety standards
- A solution now embedded into established maintenance procedures
FCC now benefits from a future ready system that delivers safe, consistent and efficient lifting performance, supported by proven technology and engineering expertise.
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