Lifting solution for complex aquarium glazing  

Specialist aquarium glazing replacement with GGR’s tracked carrier, mini spider and glass manipulator head.

An aquarium-build specialist recently contacted GGR Group to assist with a full glazing replacement of a large tank at Sea Life, a popular UK aquarium attraction chain. Appointed for their confined lifting operation expertise and specialist lifting equipment, GGR Group was tasked with delivering a safe and precise solution within a highly restricted internal environment.

As part of the upgrade, the decision was made to replace the existing glass with acrylic panels, offering several advantages for aquarium applications. Unlike glass, acrylic eliminates the green tint often seen in thick panels, providing clearer viewing, while also reducing optical distortion for a more accurate display. In addition, its improved thermal insulation properties help maintain stable water temperatures, alongside offering greater strength and impact resistance.

Completed over the course of one week, the project involved removing and installing large-format glazing panels weighing up to 650kg, all while navigating tight access routes, steep gradients, and complex installation requirements.

This project presented a unique combination of constraints that required careful planning and specialist equipment. Some doorways were as narrow as 1600mm, there was a 24deg gradient staircase measuring only 1654mm wide, there was restricted lifting headroom of 4581mm and the internal tank working areas was as tight as 1932mm. The glazing units measured up to 3300mm x 1380mm x 60mm and installation needed to take place at a -15deg angle, creating additional handling complexity.

The scale of the glazing units, combined with limited space and awkward positioning, meant that precision control and compact equipment were essential throughout every stage of the lift.

To overcome the combination of restricted access, heavy loads, steep gradients and complex installation angles, GGR Group engineered a fully integrated lifting solution, combining multiple specialist machines, each selected for its ability to perform a specific role within the operation.

Rather than relying on a single piece of equipment, the project was approached as a sequenced, multi-machine operation, ensuring efficiency, safety, and precision at every stage.

Supporting the initial logistics, the G35 pick-and-carry crane was used to lift equipment into the goods hoist. With a 3.5t capacity and no requirement for outriggers, it provided a compact and efficient solution for positioning equipment within the building.

The primary challenge, however, was transporting heavy glazing panels through the building and up a 24deg gradient staircase with minimal clearance. This was overcome using the 3.0 FX Tracked Carrier, which offered a 3000kg capacity and the ability to handle 45deg longitudinal gradients with ease.

Its tracked design, low centre of gravity, and remote-controlled operation ensured stable and precise movement, even when navigating tight spaces and timber-covered stairs. Operated by the client’s own team, the carrier proved intuitive and easy to control, even when moving large panels, measuring 1380mm wide, through a staircase just 1654mm wide.

At the centre of this project was the Unic URW-245 mini spider crane, selected for its ability to deliver high lifting capacity within extremely tight spaces.

Benefiting from a 2.4t lifting capacity and a compact width of 600mm, the URW-245 was able to pass through a 1600mm doorway with ease and lift heavy machinery and glazing within confined internal areas without disassembly.

The crane’s radio remote control system allowed operators to maintain optimal visibility and positioning, ensuring precise load placement – particularly important when working within a restricted headroom of 4581mm, where the top of the aperture sits almost flush with the ceiling.

When paired with the URW-245, the GL-UMC 1000 Glazing Manipulator Head – adapted with an additional arm to suit the size and geometry of the glazing units—delivered advanced control, including 95deg rotation, 60deg tilt, and 40deg lateral slew, ensuring precise handling and accurate installation of large panels at the required -15deg angle.

Working inside the tank introduced further constraints, with operating widths reduced to just 1932mm, while the glazing itself sat at a -15deg angle, adding further complexity to handling and removal.

The Glassboy 850 Floor Crane was lifted into the tank using the URW-245, where it enabled controlled handling of components within the confined space.

For secure lifting, the Glass Jack Glass Vacuum Lifter was used. With a capacity of up to 600kg and a dual vacuum circuit system, it provided a high level of safety and redundancy. Its adjustable chassis allowed it to be configured shorter for narrow glass fins and extended for larger triangular panels, increasing versatility on site.

Features such as: audio-visual low vacuum warnings; 360deg manual rotation and 90deg  tilt capability, allowed operators to safely manipulate and remove smaller units.

The installation phase required exceptional precision. New acrylic panels were transported into position using the 3.0 FX, moving two units at a time up the staircase.

The URW-245 first lifted the triangular and fin units into the tank, where the Glassboy 850 installed them from within the confined space. Once these units were in place, the URW-245 removed the Glassboy from the tank, ensuring it was not trapped before the main panels were installed.

With the tank clear, the GL-UMC 1000 manipulator was reattached to the URW-245. The crane then carried out the installation of the larger acrylic panels using an inside-out method—lifting the units into the tank before drawing them back into the aperture for final positioning.

The combination of advanced manipulation capability and precise crane control ensured accurate installation, even at the challenging -15deg angle.

GGR Group successfully delivered the full glazing replacement within the one-week programme, overcoming significant access and handling challenges throughout.

The coordinated use of specialist equipment enabled: the safe removal and installation of large glazing panels weighing up to 650kg; controlled transport of oversized units through tight internal access routes and a 24deg staircase; precise installation within confined spaces and restricted headroom and accurate placement of panels at a -15deg angle without compromise.

The project was completed efficiently and safely, with minimal disruption to the client’s operations.

This project highlights GGR Group’s expertise in delivering complex, confined lifting solutions for specialist environments.

By combining compact, high-performance machinery with bespoke adaptations and a carefully sequenced lifting strategy, GGR was able to overcome challenging site constraints and deliver a precise, reliable outcome.

From restricted access and steep gradients to complex installation angles, the project demonstrates GGR Group’s ability to provide innovative lifting solutions where conventional methods are not an option.