Replacing a Magnetic Belt Conveyor at 68m Radius with a 450te Crane

01. Project

A 6te conveyor lifted out through the roof at 68m

We replaced a magnetic belt conveyor that sat inside a large, complex process plant. The only way to get it out was through the roof, at 68m radius from where a crane could stand, so we took on the roof opening as well as the lift.

We removed double-skin roof sheets and the purlins in the way, lifted the old 6te conveyor out and the new one in, then spliced the purlins back together and reinstated the roof with new insulation, fixings and sealant. Taking on both parts meant the cost of a cancelled 450te lift would have been ours if the roof opening had not been ready on time. It was.

02. 3D View

Explore the lift in 3D

A model of the lift, built to the figures in our lift plan. Drag to spin it round and tap a number to see what each part of the job involved. Press Play the lift to watch the roof opening made, the old conveyor lifted out and the new one lifted in, and the roof put back, or Lift plan to see the key dimensions.

Illustrative model based on our lift plan.

03. Resources

Crane, rigging, ground and team

Crane

A Liebherr LTM 1450-8.1 on full outrigger spread with 134te of counterweight and 77m of main boom. With the hook and tackle, the load came to nearly 7te at 68m radius, and the plan narrowly but comfortably kept the boom clear of the building edge.

Crane Choice

A 500te crane needed a Y-guy that would have hit the adjacent building, which would have pushed the crane further back and called for a 750te crane. The compact 450te configuration avoided that cost. With 134te of counterweight the tail swing reached beyond the outrigger base, so the crane was set a safe distance from the next building.

Rigging

Each conveyor measured about 3.3m by 2.1m by 1.0m and was lifted on its four lifting eyes with a 6m two-leg chain, a 2.1m spreader beam and 1m slings.

Ground and Matting

Outrigger loads came to close to 180te, spread over a 6m² mat under each outrigger for a ground bearing pressure of about 30te/m². Underground services and existing plant also shaped where the crane could stand.

Team

Our Appointed Person prepared the RAMS for both the lift and the roof work. On site we had qualified sheeters, a crane supervisor, a crane operator, an Appointed Person, slinger signallers and additional riggers.

04. Timeline

From site visits to a reinstated roof

05. Outcome

What it meant for the client

The conveyor was replaced within a three-day window, with one contractor controlling both the lift and the roof. That took away the risk of delays between separate trades during planned maintenance, where every hour of downtime is expensive.

See our crane hire and contract lifting and cladding and roofing services, or read what is an all-terrain crane? and what size crane do I need?

06. Gallery