Precision Boiler Removal and Installation on a Mezzanine Level
Precision Boiler Removal and Installation on a Mezzanine Level
We successfully completed a complex boiler removal and installation project to and from a mezzanine plant room. Using specialist lifting equipment, including roller systems, pallet trucks, forklift jibs and certified lifting gear, we carefully manoeuvred both the old and new boilers within a restricted space.
All works were carried out under strict safety controls, including banksman supervision and harness protection, ensuring a smooth, efficient and incident-free installation from start to finish.
Preparation and Equipment Set Up
We began by lifting the existing boiler using a roller bar system before lowering it onto 50mm rollers. This allowed us to carefully roll the boiler clear of surrounding obstructions without disruption to adjacent equipment.
Once in a clear working area, we raised the boiler using pinch bars and positioned it onto timber blocks. A pallet truck was then placed beneath the unit, enabling us to lift and transport it safely along the Alimat tracking system to a designated pick-up point at the front edge of the mezzanine floor.
Hoisting and Lifting
To facilitate the lift from the mezzanine, we attached a forklift truck jib and positioned the hook centrally over the boiler. Using certified lifting slings and shackles connected to the manufacturer’s designated lifting points, we prepared the unit for hoisting. Under the direction of our designated banksman, the lifting hook was raised gradually until the slinging arrangement was fully secure. Once all checks were completed and we were satisfied with stability, the boiler was lifted clear of the pallet truck.
For additional safety, any operatives working near the temporary gap in the mezzanine handrails wore harnesses fitted with restricted lanyards secured to the handrail system, eliminating the risk of access to the open edge.
Removing the Existing Boiler
With the boiler safely suspended, we wheeled the staircase clear to create sufficient space for manoeuvring. The boiler was then carefully reversed away from the mezzanine before being lowered to ground level. Once the area was clear, the staircase was reinstated to fully secure the handrail system.
At ground level, we transported the boiler externally using the forklift truck and loaded it onto awaiting transport.
Offloading and Raising the New Boiler
Following delivery, we offloaded the new boilers using a forklift truck and transported them into the boiler house on forks.
After removing the forks, we reattached the forklift jib and once again positioned the lifting hook centrally over the boiler. Slings and shackles were secured to the manufacturer’s lifting points, and under our banksman’s instruction, the unit was carefully raised until the slinging configuration was confirmed secure.
Installing the New Boiler
The boiler was then hoisted clear of the ground and elevated to pass safely above the mezzanine floor level. As before, operatives accessing the handrail opening wore harnesses with restricted lanyards to ensure complete fall protection.
With the unit suspended, we temporarily moved the staircase to allow the boiler to be driven into position over the mezzanine. The boiler was then lowered onto a pallet truck, which was positioned on the Alimat system on the mezzanine floor.
Using the tracked system, we wheeled the boiler across the mezzanine and onto its prepared plinth. The final position and orientation were confirmed by the site supervisor to ensure correct alignment with services and the surrounding plant.
We then lowered the boiler onto timber blocks, removed the pallet truck, and carefully reduced the unit to floor level using roller bars to complete the installation.
Project Completion
Upon completion of the works, all lifting equipment was safely stowed, the forklift truck secured, and all loads checked. Our team ensured the site was left tidy, safe, and fully operational before departing.
This project demonstrated our capability to manage complex mechanical handling operations in restricted environments, combining detailed planning, experienced personnel, and strict safety control at every stage.