Case Study: Innovative Winch Solution for Prefabricated Warehouse Construction

Industry: Industrial Lifting / Construction

Constructing warehouse facilities with prefabricated concrete walls represents a common challenge in the construction industry. The aim is to safely and efficiently lift and position large wall sections. Controlling the movement of both the top and bottom of the wall during lifting is crucial to prevent damage and ensure worker safety. When a customer in North America faced this exact challenge, they sought an Ingersoll Rand solution that could address these industry-wide concerns.

Challenges

• Dual Movement Control: Needed to raise the top of prefabricated concrete walls at a faster rate while controlling the lower portion's movement.
• Efficient Single-Operator Use: Required a system allowing one operator to control both winches from a single station.
• Operator Comfort for Extended Use: Desired ergonomic design to accommodate long hours of operation.
• Specific Customization: Requested special features, including a unique green paint and a design factor of 5:1 for lifting safety.

Solution

We developed an innovative double-drum waterfall winch configuration:

• Custom Winch Setup: Mounted two FA2.5A-24AK winches on a common base in a waterfall arrangement (one unit positioned behind and elevated above the other).
• Integrated Control Console: Enabled the operator to control each winch independently or in tandem from a single, conveniently located station.
• Ergonomic Operator Station: Included a seating arrangement for optimal comfort during extended periods of operation.
• Tailored Specifications: Provided winches with a 5,000 lbs. capacity, 141 feet per minute speed, a 25 hp motor, and finished with the customer's requested special green paint.

Results

• Enhanced Efficiency: Achieved precise and efficient lifting of prefabricated walls, streamlining the construction process.
• Improved Safety: Reduced risk associated with complex lifting tasks through a single-operator control and ergonomic design.
• Customized Satisfaction: Met all specific requirements, delivering a solution tailored to the customer's needs.
• Industry Relevance: Offered a solution that addresses a widespread challenge in construction, showcasing our ability to meet industry demands.