Hoist & Winch Ltd.
22,000-pound SWL electric-powered wire-rope hoist unit lifted into final position at a 196-foot height.

Raising the Bar in Challenging Hoist Installations

Oct. 19, 2022
When a hoist's dimensional clearances are particularly critical, Hoist & Winch Ltd carries out a detailed survey prior to manufacture, ensuring that the complete installation can perform the required tasks with sufficient operating clearance.

Supplying, installing, load testing, and LOLER certifying a wide range of manual and powered hoist units, Hoist & Winch Ltd has extensive experience and expertise in all kinds of industrial lifting operations.

However, certain projects require special know-how, such as the installation of large-capacity, electric-powered wire-rope hoists in challenging and restricted access applications. And yet even in these situations, Hoist & Winch has a proven methodology to ensure a high-performance, efficient, safety-certified outcome for customers.

Every hoist installation is different, and most generally present some level of challenge to overcome, typically relating to the dimensional clearances of the hoist unit or the logistics of general access conditions. When the hoist unit’s dimensional clearances are particularly critical, Hoist & Winch Ltd carries out a detailed survey prior to manufacture, ensuring that the complete installation can perform the required tasks with sufficient operating clearance.

On some occasions, a pre-installation survey is required to check site/work area access conditions. Hoist & Winch Ltd will subsequently submit its Risk Assessment and Method Statement (RAMS) for approval by the customer prior to starting work. These documents detail the installation procedure, the equipment intended for use, and the hazards and risks associated with the various tasks. In addition, the documents will set out how it is possible to minimize or negate these risks.

A recent cement plant project involving challenging installation access conditions highlights how the capability and knowledge of Hoist & Winch Ltd proves extremely useful in delivering a successful outcome for customers.

This complex project involved replacing an obsolete, 22,000-pound (10-tonne) SWL (safe working load), electric-powered wire-rope hoist unit with a 196-foot (60-meter) lifting height. The task was required ahead of the cement production facility carrying out extensive modification work to its pre-heater tower. The pre-heater tower is 328 feet (100 meters) high and the existing hoist unit was located at the 196-foot (60-meter) level on a monorail beam that cantilevers out of the building for approximately 26 feet (8 meters).

Both the obsolete hoist unit and monorail beam had been dormant for many years, which meant that Hoist & Winch Ltd’s scope of supply included the load testing and thorough examination of not just the new wire-rope hoist unit, but also the monorail beam.

“Manufacturing and process plants tend to evolve over time, often compromising general access to existing hoist installations. In other instances, legacy hoists fall into disuse and become obsolete. If you are in this situation and could benefit from the input of an expert partner, please call for a no-obligation discussion about the potential solutions."

Among the first tasks was to remove the existing wire-rope hoist unit, which weighed 6,600 pounds (3 tonnes). Hoist & Winch Ltd decided to cut this down in sections using gas-burning equipment as many of the hoist parts were badly seized and not easy to dismantle in a conventional way.

Initially, the company removed these sections to a specially constructed scaffold work platform located below the hoist installation area. Each piece of the obsolete hoist was then lowered further to the nearest adjacent floor level 16m below using manual chain blocks for movement to the goods lift access located at that level.

Next, Hoist & Winch Ltd had to install the new hoist (weighing 4,850 pounds (2.2 tonnes)) in part dismantled form. The company eased the difficulty of this task by installing a temporary 6,600-pound (3-tonne) SWL motor trolley mounted, air-powered chain-hoist unit on the monorail beam and raising the new hoist unit the required 196 feet (60 meters) from the outdoor ground-floor work area. Hoist & Winch Ltd took great care with the preparation of the chain-hoist unit to ensure reliability during operation as any breakdown during the critical 196-foot (60-meter) lifting operation would require special access equipment to help resolve any issues. Hoist & Winch Ltd also carried out meticulous checks on the quality, volume, and pressure of the air supply.

The next task was to raise the complete new hoist unit to the 196-foot (60-meter) installation level. From there, Hoist & Winch Ltd used the 6,600-pound (3-tonne) SWL motor trolley mounted, air-powered chain-hoist unit to transport the new hoist unit into the building and over the temporary scaffold work platform.

From this position—after first opening up the hoist unit trolley wheels wider than the monorail beam width—the company lifted the wire-rope hoist unit into position.

To facilitate this task, Hoist & Winch Ltd deployed four 2,200-pound (1-tonne) SWL manual chain blocks suspended from each end of two specially fabricated lifting frames clipped into position on the top flange of the monorail beam.

The final tasks included electrical commissioning, assembling the hoist onto the monorail beam, and the removal of all temporary lifting equipment.

Hoist & Winch Ltd could then perform dynamic load testing of the new wire-rope hoist unit and monorail beam using a skid-mounted, certified 22,000-pound (10-tonne) test load prior to an issue with a LOLER Thorough Examination report.

As part of the dynamic load testing procedure, the outdoor cantilever section of the monorail beam was deflection-tested in accordance with BS2853 using a special long-range, outdoor-operation Leica laser mounted to a stable yet precisely adjustable tripod.

Further information is available from Hoist and Winch Ltd Unit 20, 11B Arrow Business Park Alcester Employment Park Arden Road Alcester B49 6HN Tel:  08450 171126 e-mail: [email protected] web: www.hoistandwinch.co.uk