Replacing a Century-Old Crane System at PTI Transformers

Based in Winnipeg, Manitoba, PTI Transformers is Canada’s largest 100% Canadian-owned transformer manufacturer. Specializing in custom-engineered liquid-filled transformers, PTI delivers innovative and environmentally responsible solutions that help power critical infrastructure across North America.

With transformers weighing up to 500 tons moving through its facility, safe and reliable material handling is critical to PTI’s operation. For years, PTI relied on an overhead crane system located in a key production area. When that crane reached the end of its service life, PTI turned to Acculift to help deliver a modern solution that would support their operations for decades to come.

The CHALLENGE

At the heart of PTI’s production facility was an overhead crane approaching 100 years of service. When a major component failure took the crane out of operation, PTI was faced with a critical decision: invest in a rebuild of aging equipment or replace the entire system with a modern crane designed to meet current operational demands.

The challenge extended far beyond selecting a new crane.

The existing system featured dual 51-foot bridge girders weighing approximately 35 tons each and operated at a hook height of 55 feet. Replacing the crane would require removing the existing system from inside an active manufacturing facility while minimizing disruption to production and maintaining strict safety standards throughout the project.

The complexity of the installation required detailed planning, coordination between multiple contractors, and precise execution. Sections of the building roof had to be removed to provide access for a 300-ton crawler crane. Working from outside the facility, the crane needed to reach approximately 70 feet into the building while operating alongside ongoing plant activities.

What could have been a significant operational disruption required a carefully managed solution that prioritized safety, efficiency, and minimal downtime.

The SOLUTION

After evaluating several options with PTI, Acculift recommended a complete crane replacement that would provide long-term reliability, improved safety features, and enhanced operator control.

Acculift assumed responsibility for project management, coordinating the crane design, manufacturing, removal of the existing equipment, installation of the new system, load testing, and final commissioning. This ensured a single point of accountability throughout every stage of the project, from design through commissioning.

To execute the removal and installation, Acculift partnered with Phoenix Crane, whose experienced operators and crew played a critical role throughout the project. After sections of the roof were removed, the crawler crane was positioned outside the facility and used to lift, rotate, and lower the existing crane components onto waiting transport trucks.

During installation of the new crane, the process was carefully reversed. New bridge girders were lifted into the building, rotated into position, and installed onto the existing runway system.

As with many large-scale retrofit projects, unexpected challenges arose. Small support angles along the runway structure created clearance issues that prevented the new bridge from travelling freely. Acculift’s team quickly identified the issue, developed a solution, and implemented the necessary modifications to ensure proper crane operation without impacting the project schedule.

Following installation, the crane underwent comprehensive load testing using water bag test weights before being commissioned for service.

Crane Specifications

60-ton lifting capacity
Dual 30-ton girder bridges
CMAA Class D duty rating for heavy and frequent use
Variable Frequency Drives (VFDs) on all motions for smooth, precise control
Load summation devices to prevent system overload
Blue footprint safety lighting to increase worker awareness
Integrated illumination lighting to improve visibility and reduce work area shadows

“This particular project was executed very well. There were some hiccups along the way, which you can expect on every project, especially one this large. They were handled professionally and efficiently by everyone involved, and to me, this project was a big success.”
Alastair Webster, Facilities Manager & Maintenance Supervisor at PTI Transformers

The RESULTS

The new crane system provides PTI with a modern, reliable lifting solution capable of supporting the demanding requirements of transformer manufacturing for years to come.

Beyond replacing aging equipment, the project improved safety, enhanced operator control, and reduced the risk of future downtime in one of PTI’s most critical production areas.

Despite the complexity of the work, the project was completed safely, on schedule, and on budget through close collaboration between PTI, Acculift, and Phoenix Crane.

The successful replacement ensures PTI has a modern lifting solution capable of supporting its manufacturing operations for decades to come.

Got questions?

Whether you’re replacing aging equipment, expanding your facility, or planning a complex crane installation, Acculift can help.

From system design and engineering to installation, inspections, maintenance, and project management, our team works with you to deliver safe, reliable lifting solutions that keep your operation moving.