Our previous projects showcase a wide range of bespoke lifting equipment and fabrication solutions delivered by Carl Stahl Fabrications across multiple industries, including automotive, manufacturing and heavy engineering.
From custom lifting beams, adjustable spreader beams and lifting frames through to specialist handling solutions, each project demonstrates our ability to engineer practical, safe and reliable equipment to meet specific operational requirements.
All equipment is designed, calculated and manufactured in the UK, supported by in-house engineering expertise.
Our projects regularly include structural calculations, proof load testing and inspection, ensuring compliance with BSEN 13155:2020 Cranes – non fixed load lifting attachments and supplied with a Thorough Inspection Certificate and Declaration of Conformity
The work featured highlights Carl Stahl Fabrications’ commitment to safety, precision and performance, alongside high build quality and attention to detail. This consistent approach gives customers confidence in our ability to deliver durable, compliant and bespoke lifting solutions, tailored to their application and lifting environment.
Completed Bespoke Lifting Equipment Projects
This bespoke 8 tonne lifting beam was manufactured by Carl Stahl Fabrication for a customer requiring adjustable lifting points and improved load stability during lifting operations.
The beam features a WLL of 8 tonnes and incorporates multiple adjustable lifting positions to accommodate varying load dimensions and centres of gravity. The fabricated steel construction was finished in a high-visibility yellow coating for improved site safety and identification. The modular configuration enables operators to adapt the lifting arrangement depending on the load geometry and lifting environment.
All bespoke lifting equipment manufactured by Carl Stahl Fabrication is designed in accordance with relevant British Standards and supplied with certification and proof load testing documentation where required.
Carl Stahl Fabrications designed, manufactured and supplied a pair of bespoke 1,250 kg WLL lifting clamps specifically developed for the safe handling and installation of railway sections. The clamps were fully designed, calculated and fabricated at our Rotherham facility, ensuring complete control over quality, safety and compliance throughout every stage of the project.
The clamp incorporates a robust scissor-style gripping mechanism, engineered to securely engage with railway components during lifting operations while maintaining stability and controlled load handling. The articulated linkage allows the clamp to automatically tighten under load, providing a secure grip during lifting while enabling quick and efficient release once the load is safely positioned.
Following manufacture, the lifting clamps were thoroughly inspected and load tested to verify structural integrity and safe working load performance. All equipment was produced in accordance with LOLER requirements and aligns with BS EN 13155:2020 standards for non-fixed load lifting attachments. Full certification, test documentation and a Declaration of Conformity were supplied with the finished equipment, ensuring full traceability and compliance for the end user.
Manufactured by Carl Stahl Fabrication, this bespoke 250KG spreader beam was developed to provide stable and dependable load handling for light-duty lifting applications. The compact fabricated design delivers reliable performance, durable construction and safe lifting support across workshop and industrial environments.
Designed and manufactured by Carl Stahl Fabrication, this bespoke 2 tonne adjustable H-lifting beam was developed to provide stable and controlled load handling across a range of industrial lifting applications. The adjustable lifting points allow operators to modify lifting positions to suit varying load sizes and centre-of-gravity requirements.
Designed and manufactured by Carl Stahl Fabrication, this variable weight lifting beam was engineered to accommodate multiple load capacities while providing dependable lifting performance across workshop and industrial applications.
Carl Stahl Fabrications delivered a bespoke 24-tonne lifting beam designed in a four-point configuration to meet the customer’s specific lifting requirements. While an initial concept was provided by the customer, our engineering team carried out a full design verification, producing a revised and fully compliant design prior to fabrication.
All structural calculations were completed in-house to ensure the beam met the required load capacities and safety factors. Following manufacture, the lifting beam underwent proof load testing to validate performance under load. In addition, Magnetic Particle Inspection (MPI) was conducted to identify any potential surface or subsurface defects, ensuring the highest levels of structural integrity.
Carl Stahl independently verified that the lifting beam complied fully with BSEN 13155:2020 lifting standards, with full documentation, certification and a Declaration of Conformity supplied, providing complete certification and traceability. The final design was engineered specifically to interface with a ramshorn hook, ensuring safe, secure and efficient integration into the customer’s existing lifting arrangement.
Lifting Frame
Carl Stahl Fabrications supplied a bespoke steel lifting frame, designed to support controlled and stable lifting of loads during handling and testing operations. The frame provides a rigid structure, allowing loads to be safely supported and evenly distributed during lifting.
Manufactured from heavy-duty structural steel, the lifting frame was fabricated in-house to meet project-specific requirements. The design allows for straightforward connection to standard lifting accessories, ensuring compatibility with existing lifting equipment and workshop cranes.
As with all Carl Stahl Fabrications projects, the lifting frame was produced with a focus on strength, durability and operational safety, providing a practical and reliable solution for industrial lifting applications.
8t Adjustable Spreader Beam
Carl Stahl Fabrications designed, manufactured and supplied an adjustable 3-metre spreader beam, engineered to provide flexibility and reliability across a range of lifting applications. The beam was fully designed, calculated, tested and fabricated in-house, ensuring complete control over quality, safety and compliance at every stage of the project.
The spreader beam features a double hook configuration, specifically designed to interface with a ramshorn hook, while utilising a single central lifting point for efficient load distribution. This configuration allows for straightforward connection to the lifting appliance while maintaining stability during lifting operations.
Following fabrication, the beam was load tested to verify performance and structural integrity and then painted to provide long-term protection against corrosion. All work was completed in line with BSEN 13155:2020 lifting standards, with full documentation, certification and a Declaration of Conformity supplied.
60t Spreader Beam
Carl Stahl Fabrications engineered and delivered a bespoke adjustable lifting beam with a 60-tonne capacity, developed specifically to support lifting operations within the BMW Mini manufacturing environment. The solution was fully designed, calculated, fabricated, tested and painted in-house, ensuring complete compliance with customer and industry requirements.
The adjustable design provides flexibility for varying load configurations, while maintaining stability and precise load control during lifting operations. Structural calculations were carried out by Carl Stahl’s engineering team, followed by proof load testing to validate performance under full working conditions.
The lifting beam was designed to interface directly with a ramshorn hook, allowing seamless integration with existing crane equipment. Finished in a durable painted coating for long-term protection, the beam was compliant with BSEN 13155:2020 lifting standards, with full documentation, certification and a Declaration of Conformity supplied, providing a robust and reliable lifting solution for a demanding industrial application.
1.5t Spreader Beam
Carl Stahl Fabrications designed, manufactured and supplied a bespoke 1.5-tonne spreader beam to meet a specific customer lifting requirement in regards for a dedicated lift of a crucible , where controlled load distribution and stability were essential. The beam was fully designed, calculated, tested and fabricated in-house, ensuring full oversight of quality, safety and compliance throughout the project lifecycle.
The spreader beam incorporates a central lifting point with reinforced end connections, fitted with single leg chain slings and engineered to provide secure and balanced lifting across the load. Its robust fabricated steel construction ensures durability in demanding industrial environments while allowing straightforward integration with existing lifting equipment.
Following manufacture, the spreader beam was thoroughly load tested to confirm structural integrity and safe working load performance. It was then finished in high-visibility paint for enhanced on-site safety and corrosion resistance.
All work was carried out in accordance with BS EN 13155:2020 lifting standards, with full certification, test documentation and a Declaration of Conformity supplied as standard.