Client
Fagioli S.p.A.
Category
Case Study, Software Automation Design
Tags
Heavy Industries, Transportation
Handling Systems with High Technical and Logistical Complexity

Automation for Lifting Systems – Hydraulic Strand Jacks

Fagioli S.p.A., a leading company in engineering-heavy lifting and complex transport solutions, required an automation upgrade for its lifting systems equipped with hydraulic Strand Jacks. These jacks are widely used in industries that demand the lifting and handling of exceptionally heavy and complex loads, such as civil engineering, large infrastructure construction, the oil & gas sector, and offshore platform installations.

Our team developed a modern and flexible solution that integrates a Master-Slave hardware architecture with advanced software, automating load management while minimizing human errors.

In collaboration with B&R Automation, we implemented a system that ensures maximum safety and regulatory compliance, improving operational management and exceeding the client’s initial requirements.

Adaptability to different loads and sizes

Minimization of human error

Streamlined movement operations

Simultaneous control of 2 to 258 Strand Jacks

Hydraulic Strand Jack Modernization and Automation

Developed by Fagioli in the 1990s, the original Strand Jack system relied on Windows 95 software and custom electronic hardware. An upgrade was necessary to modernize the automation, using reliable and globally accessible technologies, and to integrate crucial safety functions not present in the initial system. The aim was to develop an innovative, scalable solution built with readily available components to ensure long-term maintainability.

An additional key objective was the development of a flexible management system capable of operating with a variable quantity of Strand Jacks, ranging from 2 to 528 units, as dictated by operational requirements.

Strand Jacks were used to position the MOSE floodgates in Venice
Strand Jacks were also essential in the complex operations of demolishing the Morandi Bridge and constructing the San Giorgio Bridge

Hardware and Software Automation for Safe Lifting

Designing a system that combined high automation with maximum safety for both operators and transported loads was a primary challenge. Our solution is a Master-Slave hardware architecture: the Master unit provides centralized system control, while the Slaves manage individual jacks. By partnering with B&R Automation and utilizing their Powerlink Open Safety communication bus and X20 series products, we achieved a highly flexible and 60204-CE compliant system. This automation minimizes human error and significantly reduces installation time during lifting and lowering operations.

Safety Systems for Load Handling

We handled both hardware and software development, creating the PLC software for control and safety, and a user-friendly HMI. The system is fully self-configuring: it detects the number of jacks and automatically adjusts its logic and safety protocols. Electrical connection issues are immediately flagged for quick resolution.

The new software autonomously manages the load based on operator input, including jack type, maximum load percentage, allowed imbalance, and lifting/lowering parameters. The highly user-friendly interface simplifies jack positioning and load distribution, making operations more efficient. Lifting and lowering processes are fully automated—operators only need to select the task type and travel distance. The most critical setup operations are managed using certified safety software, preventing potential hardware or human errors.

They were also used in the modernization of Tottenham Hotspur Stadium

With our extensive expertise in industrial automation, we delivered a fully integrated hardware and software solution that is advanced, flexible, and highly efficient. This approach allowed us to create a system capable of adapting to different load sizes while minimizing human error and simplifying handling operations. The result was a significant improvement in system efficiency and safety, exceeding initial technical specifications and fully meeting the client’s needs—delivering a cutting-edge lifting system tailored to operational requirements.

For more info, contact:

Erik Levada
OPERATION DIRECTOR