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PROJECT Overview
The Barbican Centre operates one of the UK’s largest andmost specialised theatre logistics lifts, capable of transporting productionvehicles and freight weighing up to 40 tonnes directly into the undergroundloading areas of the Barbican Theatre. This lift is essential to the venue’sbackstage operations, supporting rapid set changeovers and the movement ofheavy equipment for touring productions. With the original electrical systemsapproaching obsolescence, the Barbican appointed Acute New Elevators Ltd todeliver Phase 1 of a two‑stage modernisation programme,focusing exclusively on the electrical and control infrastructure.
Phase 2, covering the mechanical refurbishment—includingmotors, hydraulic pumps, and associated heavy‑duty components—will be delivered under a separate programme and case study.
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
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
PROJECT SUMMARY
Phase 1 centred on a full electrical modernisation designedto improve reliability, enhance safety, and provide a future‑proofedcontrol platform suitable for a high‑capacity, high‑dutylorry lift. The legacy Mavercourt control system was replaced with a KollmorgenMPK411 controller, providing advanced diagnostics, improved operationalefficiency, and significantly enhanced maintainability.
A complete electrical rewire was undertaken, supported bynew galvanised metal trunking routes to restore system integrity and eliminatelong‑termfailure risks. The safety system—including doorlocks and safety circuits—was replaced in full to ensurecompliance with current standards and to improve operational resilience.
To address the unique requirement of aligning lorry trailerbeds with the theatre floor, Acute New Elevators engineered a bespoke fine‑adjustmentlevelling solution, ensuring precise, repeatable positioning under heavy loadconditions.
These upgrades delivered a substantial improvement in systemstability and operational performance, forming the foundation for theforthcoming mechanical refurbishment in Phase 2.
PROJECT Introduction
Acute New Elevators were commissioned to assess andmodernise the electrical infrastructure serving the Barbican’s 40‑tonnelorry lift. The lift plays a critical role in the theatre’s logistics chain, enabling production vehicles to betransported deep into the building’s sub‑stageareas. Reliability, precision, and compliance are essential, particularly giventhe lift’s heavy‑duty operational profile and thetight scheduling demands of live performance environments.
A detailed survey confirmed that while the mechanicalstructure remained serviceable for continued operation, the electrical systemsrequired a full modernisation. This allowed Phase 1 to focus solely onelectrical and control upgrades, with mechanical works scheduled separately tominimise disruption and maintain operational continuity.
Challenge
Phase 1 presented several technical challenges:
• Theoriginal Mavercourt control system was outdated, difficult to support, andlacked modern diagnostic capability.
• Wiringroutes and trunking had deteriorated over time, increasing the risk of faultsand unplanned downtime.
• Thesafety system no longer met current regulatory expectations, requiring a fullredesign and replacement.
• Thelift’s operational context—frequent loading of heavy vehicles and the need forprecise floor‑to‑lorry alignment—demanded a levelling system capable of fine, repeatableadjustments under extreme load.
• Allworks had to be delivered within a live theatre environment, requiring carefulcoordination to avoid disruption to scheduled performances and backstagelogistics.
These constraints required a tailored engineering approach,ensuring that all new electrical systems were compatible with the existingmechanical arrangement pending Phase 2.
Solution
A comprehensive electrical modernisation package wasdeveloped, centred on the installation of a Kollmorgen MPK411 control platform.This provided advanced control logic, improved energy efficiency, and enhanceddiagnostic capability, enabling faster troubleshooting and more proactivemaintenance.
Key elements of the Phase 1 solution included:
• Fullelectrical rewire, supported by new galvanised metal trunking to restore systemintegrity and ensure long‑term resilience.
• Completesafety system replacement, including new door locks and safety circuits, fullycompliant with current standards.
• Bespokelevelling solution engineered to deliver fine‑adjustment accuracy for seamlessalignment between lorry trailer beds and the theatre floor.
• Integrationof modern electrical components within the existing mechanical footprint,ensuring compatibility with the forthcoming mechanical refurbishment in Phase2.
All systems were designed to withstand the high‑load,high‑dutyoperational profile of a 40‑tonne lorry lift, ensuringreliability during peak production periods.
Result
Following a structured design and coordination phase, thefinal specification for Phase 1 was agreed with the client and a clearprogramme established. All new control and electrical components weremanufactured, 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, issuingregular progress reports and ensuring full transparency around programmemilestones, commissioning stages, and operational considerations.
Once installation was complete, a full programme of testing,commissioning, and verification was carried out, with all tests witnessed bythe client. The upgraded electrical systems delivered improved reliability,enhanced safety, and the precise levelling accuracy required for safe andefficient backstage logistics.
Phase 1 has now provided a robust, compliant, and future‑proofedelectrical foundation for the Barbican’s lorry lift.The project demonstrated Acute New Elevators’capability in delivering complex, large‑scale modernisation works withinsensitive, high‑profile environments. Phase 2 the mechanicalrefurbishment will follow, once works are completed first quarter 2026.
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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