Friday 14th July 2023
Introduction
This case study showcases a remarkable project undertaken by our service engineers team, involving the replacement of an old, irreparable 1980s Verlinde wire rope hoist with a new Verlinde VT3 wire rope hoist at a cement factory. With a lifting height requirment of 42 meters, the installation posed significant challenges, particularly due to the factory's limitations, making it the toughest install we've accomplished to date. This case study details the innovative approach and determination displayed by our team to successfully complete the project while ensuring the utmost safety for both our personnel and equipment.
Project Background
The cement factory, recognising the importance of the hoist for their operations, had no choice but to replace the worn-out Verlinde hoist. The decision to invest in a new Verlinde VT3 wire rope hoist promised improved performance and efficiency. However, the factory faced a major hurdle: there was no feasible way to lift the units through the roof using a mobile crane.
The Challenge
The installation of the new VT3 wire rope hoist at the cement factory presented a series of daunting challenges that tested the ingenuity and perseverance of our team. Firstly, the factory's old Verlinde wire rope hoist was irreparable, leaving us with the task of removing it. However, the factory's limited access meant that we couldn't employ a mobile crane to lift the heavy units through the roof.
Undeterred, we devised an innovative solution - utilizing an electric hoist designed for complex installations. By fabricating T-bars and utilizing chain blocks, we skillfully lowered the hoist to a scaffold, where it was meticulously rigged to descend through a narrow shaft within the building to the ground. The entire process had to be replicated in reverse for installing the new VT3 hoist. Furthermore, the challenging environment with extreme heat, pervasive concrete dust, a towering height of 39 meters, and disruptive noise further intensified the complexity of the project.
Our Step by Step Solution Strategy:
- Introduction of an Electric Hoist: To facilitate complex installs, the team utilized an electric hoist specifically designed for such scenarios
- Fabrication of T-Bars and Chain Blocks: T-bars were fabricated to lower the hoist onto a scaffold using chain block
- Rigging the Electric Hoist: The electric hoist was carefully rigged to lower the old hoist through the building's shaft to the ground.
- Reverse Process for New Hoist: The same process was applied in reverse to install the new VT3 hoist.
- Custom Wire Brushes: The new hoist was equipped with custom-made wire brushes to clear the runway of excess cement buildup, thus enhancing the drive and idle wheels' longevity.
Execution and Implementation:
The step-by-step process of the hoist replacement was meticulously executed, ensuring all safety measures were strictly adhered to. Effective communication and coordination between our team and the cement factory's personnel played a crucial role in the successful completion of the project. Unforeseen challenges were addressed promptly, thanks to our team's adaptability and problem-solving skills.
Improved Perfrmance: The new VT3 wire rope hoist delivered superior performance, enhancing the efficiency of the cement factory's operations.
Extended Equipment Lifespan: The custom-made wire brushes prevented excess cement buildup, prolonging the working life of the drive and idle wheels.
Conclusion
Despite the numerous obstacles faced during the installation of the VT3 wire rope hoist, our team's determination, innovation, and unwavering commitment to safety allowed for the successful completion of the project. This case study exemplifies our capability to tackle even the most demanding tasks, ensuring client satisfaction and operational efficiency.
Learn more about our full range Verlinde Wire Rope Hoists here