ICL Cable Gantry Replacement – Overcoming Complex Engineering Challenges

ICL operates a Potash mine on the North Yorkshire coast, where infrastructure must withstand harsh environmental conditions. Constant exposure to a salt-laden atmosphere, heavy rain, and strong coastal winds had significantly deteriorated one particular conveyor gantry, meaning its working life was rapidly coming to an end.

The Challenge

Ordinarily, demolishing and replacing a conveyor gantry would be a straightforward process, completed without risk or disruption to plant operations. However, in this instance, the project presented a unique set of challenges:

🔹 The gantry didn’t just support a conveyor system—it also provided critical structural support for a vast network of electrical cables.

🔹 These cables distribute power to essential plant services and could not be isolated or disconnected at any point.

🔹 The primary design challenge was determining how to safely support the existing cables while enabling the controlled demolition and replacement of the original gantry.

Innovative Engineering Approach

Following careful planning and consultation with ICL, Wright Engineering developed a bespoke engineering solution that ensured the seamless transition between old and new infrastructure without disruption:

✔ A replacement support structure was designed and fabricated, incorporating vertical hangers to safely carry the existing cable trays.

✔ The new gantry was constructed over the top of the original structure, ensuring the cables remained supported at all times.

✔ Once fully installed and secured, the corroded gantry was carefully dismantled, section by section, in a controlled and methodical manner.

✔ The new gantry was coated with a high-grade protective finish, ensuring longevity and resistance to corrosive coastal conditions.

The Outcome

The successful execution of this project delivered multiple key benefits:

✅ Zero disruption to critical plant operations.

✅ No damage to existing electrical infrastructure.

✅ Extended operational lifespan, with a durable, corrosion-resistant structure built to withstand the harsh environment.

✅ Delivered on time, with precise planning ensuring minimal disruption to site activities.

This project is a perfect example of Wright Engineering’s ability to tackle complex engineering challenges, delivering practical, safe, and efficient solutions in demanding environments. Well done to the team for another outstanding project! 👏

See more of what we do: www.wrighteng.co.uk

#engineering #infrastructure #conveyor