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Case Study: Liberty Steel – Improving Crane and Asset Safety
The challenge: Preventing collisions between cranes
Liberty Steel Brinsworth, a narrow strip mill operational since 1957, processes slab into coil for various international sectors, including the agricultural and automotive industries. They faced a unique and critical safety challenge in a single bay: preventing their four overhead cranes from colliding with the semi-portal cranes operating beneath them.
The overhead cranes carry heavy slabs across the bay while the lower semi-portal crane is actively “descaling” (removing imperfections from the slab). This setup creates a high-risk area. Up until this point, collision avoidance relied solely on the crane driver’s skill and experience, a reliance which became unacceptable after “a couple that were a little bit close.” They needed an extra level of defence to protect personnel and prevent damage to the valuable semi-portal crane asset.
The solution: A vehicle safety and asset protection system
Liberty Steel approached ZoneSafe for a solution, recognising that this was a “unique requirement that wasn’t fulfilled by any of the other safety systems” they had in place (which included laser distance measurement).
They installed a transmitter unit on each overhead crane hoist (referred to as “Halos”) and warning sirens and flashing lights on the semi-portal cranes below.
After close collaboration and testing, an optimum antenna range was established to suit Liberty Steel’s working requirements. The most important factor was finding a system that was “simple” but allowed them to vary the distance to avoid “nuisance alarms,” which could cause operators to lose trust in the system. As Crane Operator Stuart Williams stated, the system provides a visual and audible warning that can be easily seen and heard by the overhead crane operators.
The result: An extra layer of defence and enhanced safety
The ZoneSafe system provides a critical warning that was previously missing, eliminating the sole reliance on driver skill. The system operates as an “active detection” system, crucial when multiple overhead cranes are operating at once.
If an overhead crane’s load gets too close to the semi-portal crane, the “Halo” transmitter initiates a flashing light and an audible siren on the semi-portal crane, giving an instant warning to the overhead crane operator: “I’m getting a little bit close here.”
This extra layer of protection has significantly enhanced safety and protected valuable assets. Importantly, it has improved the drivers’ working environment: “it gives them that extra level of confidence that it’s not just all on them.” By adding this system, Liberty Steel ensured drivers had the reassurance needed to reduce stress and prevent incidents.
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