Caldwell Low-Headroom Beam Supports Safer Steel Coil Handling

The Caldwell Group Inc. has engineered a low-headroom multiple spread lifting beam designed to improve safety and efficiency in steel coil handling applications. The 7.5-ton-capacity Model 20S beam is being used by JEC Service Company, Inc. at its sheet metal fabrication facility in Rockford, Illinois.

The beam is installed below the hook of a top-running double-girder crane system and is part of an integrated lifting solution supplied by Mass Crane & Hoist Services, Inc. Measuring 77 inches in length and featuring a custom single-pin bail, the beam is designed to load 60-inch sheet metal coils into a Vicon coil processing machine.

At JEC’s facility, where ductwork for the HVACR industry is produced, safety was a primary consideration in selecting the system. “Our entire mission in purchasing this system was safety — minimizing hazards and keeping material handling contained within a controlled area,” said Al Seelig, head of sheet metal operations at JEC. “This beam delivered exactly what we needed.”

Each coil cradle handled by the crane weighs approximately 10,000 pounds, requiring consistent lifting performance as production demands change. Limited headroom in the facility made it necessary to maximize available vertical space for both operational efficiency and safe material handling.

According to Ryan Sullivan, project manager at Mass Crane, the beam addressed these constraints. “We engineered the crane system complete with columns and runways, but the challenge was ensuring JEC could safely maneuver coils within a confined space,” he said. “Caldwell’s low-headroom beam allowed them to maximize hook height, making it possible to lift and position coils safely — even stacking one over another on the rack.”

To improve integration with the hoist system, Caldwell modified the connection point from a standard lifting eye to a single-pin bail, increasing usable headroom. The beam is part of the Model 20 product line, which includes multiple standard configurations with varying capacities and spreads, as well as options for additional components and customization.

The lifting beam is used in conjunction with a Vicon coil processing line, a semi-automatic system that performs de-coiling, punching, notching, shearing and roll-forming of sheet metal into finished ductwork components.

“The beam had to account for the weight of the coil, the spindle and the lifting device itself,” Seelig added. “It’s a critical part of keeping our operation running safely and smoothly.”

The system reflects ongoing efforts to address safety and efficiency challenges in steel handling applications, particularly in environments where space limitations impact lifting operations.