Mini crawler cranes: Safer lifting in the tight spaces of a chemical manufacturing plant

CF Industries integrated Movex Innovation’s XC-270 Mini Crawler Crane as a complementary lifting solution.

The goal was not to replace the plant’s larger cranes, including equipment with capacities up to 90 tons; it was to close the gap between manual lifting and large lifting equipment.

The XC-270 gave the maintenance team an ultra-compact electric machine that could be used in restricted areas, remotely controlled, and deployed for loads that were too risky or inefficient to handle manually.

The new setup typically involves 2 workers: 1 operator using the remote control and 1 spotter guiding the operation from another angle.

This alone changes the way the work is done. Fewer workers need to place their hands on the load. The operator can stay at a safer distance. The spotter helps maintain visibility and control. The job becomes more controlled without becoming overcomplicated.

CF Industries also added a manual hoist at the end of the boom to improve precision and load adjustment. This gave operators even more control over load positioning, especially in tight areas where small adjustments make a huge difference.

The team chose the XC-270 because it was compact, intuitive, and easier to use than more complex spider-crane-style alternatives. It fit the company’s internal standards and was easier to integrate into their lifting and risk assessment processes.

Initial training was provided by Movex Innovation, and adoption by the maintenance team was fast and straightforward.

For CF Industries, the XC-270’s value comes from the work it makes safer, simpler, and easier to plan.

Less manual lifting and lower exposure to injury

The most important result is worker safety. Reducing manual handling helps protect workers, but it also protects the operation from the ripple effects of an injury: sick leave, compensation costs, replacement labour, delayed maintenance work and added pressure on crews that are already stretched. When fewer people need to handle a heavy or awkward load, there are fewer chances that a single lift will turn into a bigger operational problem.

From 4–6 workers to 2 workers on certain jobs

As mentioned previously, before the XC-270, some handling tasks required 4 to 6 workers.

With the mini crawler crane, many of those tasks can now be done with 2 people: one operator and one spotter. Fewer people are tied to one lift, which means the rest of the team can stay focused on other maintenance work.

For a rotating maintenance group of approximately 12 employees, that flexibility is important. Labour is not sitting around waiting for a lift to be coordinated. The team can allocate people more efficiently and keep more work moving simultaneously.

Faster execution and better productivity

The XC-270 also helped improve productivity. When a lift no longer requires several workers and a more complicated setup, the job can move faster.

Teams spend less time figuring out how to position larger equipment or coordinate manual handling. They have a compact machine ready for the types of loads that used to create delays. It definitely speeds up task execution and facilitates daily maintenance planning.

Access to areas where traditional equipment could not fit

The XC-270 gave CF Industries a way to work in areas where larger equipment simply could not access, such as congested plant zones, pipe alleys, areas under structures, and maintenance locations where access is restricted.

It also changed the mood around difficult jobs. When workers know they have the right tool for the lift, the work is less frustrating, less complex and less physically draining.

A safer way to move a 400 lb radiation shielding cylinder

One of the clearest advantages of the mini crawler crane involved a radiation shielding cylinder weighing approximately 400 lb.

Using the XC-270, staff could lift and transport it mechanically, reducing physical effort and keeping workers away from the highest-risk parts of the move.

Electric operation that improves the work environment

The XC-270 is 100% electric, which makes it well-suited to indoor and congested industrial environments.

There are no exhaust emissions during operation. Noise is reduced. The equipment can be used in shops and enclosed areas without creating the fumes and disruption associated with combustion equipment. It also eliminates the need for ventilation and PPE in many businesses.

Battery autonomy has been sufficient for CF Industries’ applications, with simple overnight charging. The team also optimized the way it uses the machine by transporting it closer to the work area with a forklift instead of driving it long distances through the plant.

Strong user adoption and award-level recognition

The XC-270 has been well-accepted by the maintenance team and is being used more as crews identify the right applications for it.

The project was also selected as a finalist for CF Industries’ Wilson Safety Award, an internal recognition program that highlights innovative safety improvements across the company’s sites.