GRC Engineering was commissioned by BMI Group to replace a vibratory sand screen situated at a high level within their Wigan facility. The sand screen, in operation for over two decades, was located approximately six metres above ground level, surrounded by large conveyors and hoppers integral to the sand processing system. Its confined position inside an enclosed structure posed significant logistical hurdles. Several engineering firms had assessed the project and concluded that replacing the unit would require dismantling part of the building roof and deploying large cranes—methods that would have drastically increased project costs and led to prolonged operational downtime. BMI Group needed a smarter, less invasive solution that could deliver results without disrupting plant operations.
Our solution
GRC Engineering approached the challenge with a fresh perspective and a commitment to finding a practical, cost-effective solution. Beginning with a comprehensive assessment of the installation environment to identify all constraints and opportunities. The team developed a non-invasive method of removing and installing the screen that did not require roof removal or the use of cranes. A suitable replacement sand screen was sourced from a trusted specialist supplier. The complex removal and installation process was then completed safely and efficiently within just three days, all while working within the limited space available.
Project results
The project was completed smoothly and efficiently. BMI Group was able to avoid major structural alterations to their facility, experience minimal disruption to ongoing operations, and complete the work at a cost significantly lower than previous estimates. The rapid three-day turnaround also ensured that downtime was kept to an absolute minimum.
Most rewarding aspect
The most satisfying part of the project was proving that the job could be done efficiently and safely without resorting to costly, disruptive methods. Earning the client’s trust and delivering exceptional results under tight constraints highlighted the value of our experience, adaptability, and commitment to problem-solving.
“We were very impressed with the can-do attitude of the GRC team. Everything from the initial survey to the more detailed planning of the job and the execution by the site team was very professional and positive. The job was done safely in an impressive timeframe.”
