How We Solved Chronic Electrical Cable Failures on an Energy-from-Waste Grab Crane

Energy-from-waste plants rely heavily on the reliability of their waste feed systems — and in particular, the grab cranes that feed fuel from the bunker into the furnace.

When grab crane reliability suffers, so does the entire plant’s performance.

At BIA Engineering Ltd, we were engaged to help a plant facing chronic reliability problems with the electrical cable system on their waste grab crane.

The Problem

The issue centred on the large, multi-core electrical cable feeding the grab:

• Over 30 metres of heavy cable hanging when the grab was at the bottom of the bunker

• 30+ 2.5mm² cores, adding significant weight and stiffness

• The OEM’s solution — a metal cable sock and inertia reel — proved inadequate for the real-world demands of the plant

• Excessive tension and cable movement caused frequent pullouts from the connector socket

• When this occurred, all electrical functions on the grab were lost — leading to unplanned downtime and emergency interventions

• Repairs were needed weekly — causing significant maintenance cost and disruption

Our Solution

Rather than attempting to redesign the entire cable system — which would have required major plant works and extended downtime — we took a practical, focused approach.

We designed and implemented a robust mechanical bracing system:

• A large clamp to secure the cable firmly against the grab

• Designed to take cable weight off the connector socket

• Engineered to withstand dynamic movements of the grab operation

• Simple to install and maintain

The Outcome

• Immediate improvement in reliability

• Cable pullout incidents reduced from weekly to once every 3–4 months

• Significant reduction in contractor callout costs and maintenance time

• Operators gained confidence in crane reliability — improving plant throughput stability

Why It Matters

Many plants suffer with OEM design compromises that don’t hold up under real-world operating conditions.

At BIA Engineering Ltd, we focus on practical, results-driven solutions — not theoretical fixes.

In this case, a simple, robust mechanical intervention delivered far greater value than expensive, complex redesigns.

Engineering solutions beyond expectations means doing what works — and delivering lasting results where others simply tolerate ongoing failure.

If your plant is fighting grab crane reliability issues, we can help.