The Challenge
Aerfin’s new facility in Newport was constructed on piled ground, a necessity due to the region’s well-documented poor soil conditions. As a result, installing a free-standing gantry crane was not feasible, as the required loadings and span would have necessitated additional piling—an option that was both cost-prohibitive and physically unviable.
To overcome this, Lloyds Beal undertook a detailed structural assessment, evaluating the residual load capacity within the existing portal frame. This involved extensive collaboration with the original building designers, numerous structural calculations, and on-site meetings to ensure the proposed gantry system could integrate seamlessly with the building’s framework without compromising its integrity.
A key challenge was the irregular valley column arrangement, which left 16m clear spans between uprights. This required exceptionally large gantry beams, ultimately leading to the selection of 910x305x224 kg/m steel sections—an engineering feat in itself. Further refinements resulted in a beam design incorporating 4m-centre gussets on both sides and 50mm square rail welding to accommodate the crane wheels.
The initial box girder design calculations indicated that the crane’s tare weight would be 30 tons, with an operational lifting capacity of 20 tons (10t+10t). These load considerations were critical to the overall structural design, ensuring the installation met both operational and safety requirements. Given Aerfin’s reliance on Lloyds Beal for this high-stakes project, precision and flawless execution were paramount.
The Solution
Through innovative design and collaboration with Vale Consultancy, Lloyds Beal developed a solution that met Aerfin’s operational requirements while ensuring full structural integration with the existing portal frame structure (designed and manufactured by Adstone Construction). This approach eliminated the need for additional piling, making the installation both feasible and cost-effective.
To facilitate the crane system, Street Crane was commissioned to manufacture the box girders, while Lloyds Beal took on the fabrication of the 200 metres of gantry rail required for the system’s operation. Given the project’s scale, steel procurement was a critical factor—sourcing beams of this size was only possible from a single mill in the UK capable of rolling the required sections.
The project demanded extensive fabrication, welding, painting, drilling, and cutting, with meticulous site engineering to ensure every component aligned precisely. Countless hours of expert craftsmanship and rigorous quality control culminated in a seamless installation, delivering a robust and efficient lifting solution for Aerfin’s new facility.
The Results
The completed 20-ton (10t+10t) overhead gantry crane, supported by 200 metres of gantry rail, has been successfully integrated into Aerfin’s 200,000 sq/ft facility at Indurent Park, Newport. Designed to operate seamlessly within the existing portal frame structure, with 16m clear spans, the system enables the efficient tandem lifting of aircraft engines and components, meeting Aerfin’s precise operational needs.
This project stands as a testament to Lloyds Beal’s expertise in bespoke lifting solutions, delivering a robust, high-performance system tailored to Aerfin’s expansion. Congratulations to Aerfin on their continued growth in the aerospace sector, and a well-earned recognition to the Lloyds Beal team for their dedication and engineering excellence.
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