Bespoke Overhead Travelling Crane for Oxford Flow

Project Summary

• Client: Oxford Flow, innovators in industrial valves and regulators
• 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 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.

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