Electrical Modernisation of 40 tonne Lorry Lift

CASE STUDY

About

PROJECT INTRODUCTION

Acute New Elevators were commissioned to assess and modernise the electrical infrastructure serving the Barbican’s 40‑tonne lorry lift. The lift plays a critical role in the theatre’s logistics chain, enabling production vehicles to be transported deep into the building’s sub‑stage areas. Reliability, precision, and compliance are essential, particularly given the lift’s heavy‑duty operational profile and the tight scheduling demands of live performance environments. A detailed survey confirmed that while the mechanical structure remained serviceable for continued operation, the electrical systems required a full modernisation. This allowed Phase 1 to focus solely on electrical and control upgrades, with mechanical works scheduled separately to minimise disruption and maintain operational continuity.

History

A beautiful place and well located near nature

Location

Wellness hotel in the heart of nature and mountains

Services

We offer a wide range of services in our hotel

Challenge

Phase 1 presented several technical challenges: • The original Mavercourt control system was outdated, difficult to support, and lacked modern diagnostic capability. • Wiring routes and trunking had deteriorated over time, increasing the risk of faults and unplanned downtime. • The safety system no longer met current regulatory expectations, requiring a full redesign and replacement. • The lift’s operational context—frequent loading of heavy vehicles and the need for precise floor‑to‑lorry alignment—demanded a levelling system capable of fine, repeatable adjustments under extreme load. • All works had to be delivered within a live theatre environment, requiring careful coordination to avoid disruption to scheduled performances and backstage logistics. These constraints required a tailored engineering approach, ensuring that all new electrical systems were compatible with the existing mechanical arrangement pending Phase 2.

solution

A comprehensive electrical modernisation package was developed, centred on the installation of a Kollmorgen MPK411 control platform. This provided advanced control logic, improved energy efficiency, and enhanced diagnostic capability, enabling faster troubleshooting and more proactive maintenance. Key elements of the Phase 1 solution included: • Full electrical rewire, supported by new galvanised metal trunking to restore system integrity and ensure long‑term resilience. • Complete safety system replacement, including new door locks and safety circuits, fully compliant with current standards. • Bespoke levelling solution engineered to deliver fine‑adjustment accuracy for seamless alignment between lorry trailer beds and the theatre floor. • Integration of modern electrical components within the existing mechanical footprint, ensuring compatibility with the forthcoming mechanical refurbishment in Phase 2. All systems were designed to withstand the high‑load, high‑duty operational profile of a 40‑tonne lorry lift, ensuring reliability during peak production periods.

Result

Following a structured design and coordination phase, the final specification for Phase 1 was agreed with the client and a clear programme established. All new control and electrical components were manufactured, configured, and tested within the agreed production window. Installation works were completed on time and on budget. Acute New Elevators maintained a strong on‑site presence throughout, issuing regular progress reports and ensuring full transparency around programme milestones, commissioning stages, and operational considerations. Once installation was complete, a full programme of testing, commissioning, and verification was carried out, with all tests witnessed by the client. The upgraded electrical systems delivered improved reliability, enhanced safety, and the precise levelling accuracy required for safe and efficient backstage logistics. Phase 1 has now provided a robust, compliant, and future‑proofed electrical foundation for the Barbican’s lorry lift. The project demonstrated Acute New Elevators’ capability in delivering complex, large‑scale modernisation works within sensitive, high‑profile environments. Phase 2 the mechanical refurbishment will follow, once works are completed first quarter 2026.

testimonial

"If you need some advice on choosing which lift will meet your requirements, discuss a project, request a quotation or find out more about Acute Elevators, please contact a member of our team."

GALLERY

History

A beautiful place and well located near nature

Location

Wellness hotel in the heart of nature and mountains

Services

We offer a wide range of services in our hotel

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SPEAK TO THE TEAM

If you need some advice on choosing which lift will meet your requirements, discuss a project, request a quotation or find out more about Acute Elevators, please contact a member of our team.