Two Grove GMK5150 XL Cranes Complete 22-Tonne Substation Lift Under Height Restrictions at Gatwick Airport
- Meagan Wood
- Feb 17, 2025
- 5 min read
Updated: Jan 2
30-Second Takeaway
Two Grove GMK5150 XL all-terrain cranes from Southern Cranes & Access successfully installed a 22-tonne electrical substation at London Gatwick Airport while operating under a strict 25-meter height restriction. The lift was completed without disrupting flight operations, using a dual-crane configuration to distribute the load and comply with UK axle load regulations. The project marks the third similar installation carried out by Southern Cranes & Access at the airport in recent months
Significant engineering work near the main control tower at London Gatwick Airport proceeded without disrupting flight operations, thanks to the deployment of two Grove GMK5150 XL mobile cranes from Southern Cranes & Access.
Clive Sadler, Director of Southern Cranes & Access, elaborated on the rationale behind choosing the Grove cranes for the substation installation:
“Our objective was to complete all operations beneath a 25-meter height to avoid necessitating a suspension of aircraft movements. Given that the substation features eight lifting points, utilizing a single crane would have required an additional longitudinal spreader beam. Therefore, it was prudent to distribute the load across two cranes. We opted for the GMK5150XL models due to their impressive counterweight capacity (30.9 tons within a 16.5-ton per-axle limit), allowing us to minimize the need for extra support vehicles, ultimately saving both time and costs. Additionally, the cranes boast a compact footprint and present a visually appealing profile in our new livery," he stated.
All personnel from Southern Cranes & Access on-site were required to possess full accreditation from Gatwick Airport prior to the lift. The GMK5150 XL cranes underwent rigorous screening before being granted access through a designated security gate.
Before the installation, Southern Cranes & Access retrieved the substation from the B&S Group factory, where it was equipped with Schneider electronic systems for UK Power Networks. The transport of the 22-ton module, along with supplementary steel legs, stairs, and walkways, was conducted under escort due to its 4.1-meter width (measuring 12.8 meters in length and 3.6 meters in height). As the substation exceeded the width limit for the standard security gate, alternative arrangements were necessary to utilize a different gate and escort the substation along the main taxiway amidst aircraft movements.
Despite the complexities involved in this project, the installation was successfully completed without any incidents and adhered to the established schedule. This marks the third such installation that Southern Cranes & Access has accomplished at Gatwick Airport in recent months.
About Southern Cranes & Access
Founded in 1997, Southern Cranes & Access is a UK-based, family-owned lifting and access specialist providing mobile crane hire, contract lifting, and powered access solutions. Operating primarily across southern England, including Sussex, Surrey, Berkshire, Hampshire, Greater London, and surrounding regions. The company supports projects across infrastructure, aviation, utilities, construction, industrial maintenance, and specialist engineering sectors.
Southern Cranes & Access has built a strong reputation for operating in highly controlled and safety-critical environments, including live airports, rail corridors, urban centers, and restricted-access sites. Its operations routinely involve complex lift planning, multi-crane configurations, and coordination with multiple stakeholders, including airport authorities, utility providers, principal contractors, and regulatory bodies.
The company places strong emphasis on compliance, accreditation, and operational readiness, ensuring personnel meet site-specific requirements such as airport airside passes, safety certifications, and project-specific inductions. Its fleet strategy prioritizes modern, versatile all-terrain cranes capable of balancing lifting performance with transport efficiency under UK road regulations.
By combining experienced personnel, detailed lift engineering, and a modern crane fleet, Southern Cranes & Access regularly undertakes technically demanding lifts where precision, timing, and operational continuity are critical.
Visit Website 🔗 https://www.southerncranes.co.uk
About Grove All-Terrain Cranes
Grove, a brand of The Manitowoc Company, is one of the world’s leading manufacturers of mobile hydraulic cranes. Grove all-terrain cranes are designed to operate effectively both on public roads and on demanding job sites, combining multi-axle mobility with high lifting capacities and compact working envelopes.
The GMK5150XL is part of Grove’s mid-to-heavy class all-terrain lineup and is widely used for infrastructure, energy, industrial, and urban construction projects. Key characteristics of Grove all-terrain cranes include the ability to transport significant counterweight within legal axle load limits, efficient setup on confined sites, and the integration of advanced crane control systems for precise load handling.
Grove cranes are frequently selected for projects where logistical efficiency, regulatory compliance, and lifting accuracy must be balanced particularly in environments where additional transport vehicles, extended crane footprints, or operational downtime are undesirable.
Learn More 🔗 https://www.manitowoc.com/brands/grove
About The Manitowoc Company
Founded in 1902, The Manitowoc Company, Inc. is a global provider of engineered lifting solutions with more than 120 years of experience serving construction, infrastructure, energy, industrial, and port markets. The company designs, manufactures, distributes, and supports a comprehensive portfolio of lifting equipment through its globally recognized brands, including Grove, Manitowoc, Potain, National Crane, Shuttlelift, and others.
Manitowoc’s operations span product development, manufacturing, aftermarket support, and digital crane technologies. The company invests heavily in crane control systems, operator assistance technologies, and lifecycle support services to improve safety, efficiency, and uptime across its equipment range.
Through its global service network, Manitowoc supports customers throughout the full lifecycle of their equipment from commissioning and training to maintenance, refurbishment, and parts support making it a long-term partner for contractors operating in complex lifting environments.
Learn More 🔗 https://www.manitowoc.com
Frequently Asked Questions
What was the scope of work at Gatwick Airport?
The project involved the delivery and installation of a 22-tonne electrical substation near Gatwick Airport’s main control tower. The scope included off-site collection, escorted transport, airside access coordination, dual-crane lifting operations, and precise placement within a live airport environment.
Why is lifting work near airport control towers especially challenging?
Work near control towers requires strict height limitations, continuous coordination with air traffic control, and adherence to airside safety regulations. Any lifting operation that exceeds defined height limits can trigger suspension of aircraft movements, leading to significant operational and financial impacts.
Why was a 25-meter height restriction imposed on this lift?
The 25-meter height limit was imposed to ensure that crane operations did not infringe upon protected airspace or interfere with aircraft approach and departure paths. Staying below this threshold allowed flight operations to continue uninterrupted.
Why was a dual-crane lift selected for this installation?
The substation had eight designated lifting points, making load distribution critical. Using two cranes reduced hook height, eliminated the need for additional spreader beams, and improved control of the load during positioning, all essential under tight height restrictions.
Why were Grove GMK5150XL cranes specifically chosen?
The GMK5150XL offers a combination of high lifting capability and the ability to carry up to 30.9 tonnes of counterweight while remaining within the UK’s 16.5-tonne per-axle road limit. This reduced the need for additional support vehicles and simplified logistics in a constrained airport environment.
How does counterweight transport affect crane selection in the UK?
UK road regulations place strict limits on axle loads. Cranes that can carry larger counterweights legally reduce the number of additional transport movements required, improving efficiency and minimizing disruption, particularly important in secure or congested sites.
What role did crane control systems play in this lift?
Advanced crane control systems enabled precise load management, smooth hoisting, and accurate positioning of the substation. This level of control is essential when operating close to infrastructure, personnel, and live airport operations.
What security measures were required to operate airside?
All personnel required full Gatwick Airport accreditation. The cranes underwent detailed security screening and accessed the site through designated airside gates under escort, following airport security protocols.
How was the substation transported to the airport?
The substation was collected from the B&S Group factory and transported under escort due to its 4.1-meter width. Additional components such as steel legs, stairs, and walkways were transported separately to manage size and weight constraints.
Why did transport require alternative routing within the airport?
The load exceeded the width limit of the standard security gate, requiring alternative gate access and escorted movement along the main taxiway while aircraft operations continued.
