Terex cements relationship with CEMEX

  • Fully automated crane system boosts productivity
  • Controls housed in a air conditioned cabin
  • State-of-the-art PLC operation

Terex Material Handling’s Demag Service team has completed a major refurbishment and upgrade of a Demag crane system at the CEMEX cement production facility in Rugby. The plant is CEMEX’s largest UK operation, working 24/7 and outputting over 5,000 t of cement per day.

The 28 m span, 18 t SWL Demag double girder, overhead travelling crane, equipped with a 6 t capacity bucket, is situated in the plant’s natural gypsum, synthetic gypsum and limestone store. Some 30 lorries per day deliver raw material, tipping it into reception pits. The crane moves material from the reception pits to the appropriate storage bays, before further transfer to the hoppers, which feed the plant’s mills via conveyors.

CEMEX’s Operations & Technology team recognised that heat and dust in the arduous working environment had been causing system faults. In addition, some of the crane system’s components, including the Siemens S5 PLC, were no longer supported by manufacturers. To guard against the risk of critical crane system downtime, which may impact upon production efficiency, CEMEX engineers and Demag service technicians worked together closely to engineer a solution to provide improved performance and increased capacity.

The Demag crane’s existing controller was updated with a state-of-the-art Siemens’ S7 PLC, facilitating fully automatic control via an interface with the CEMEX master control room. The refurbishment programme also transferred the control systems to a bespoke 8 x 2 m cabin, which had been prefabricated in Germany and delivered to site as a plug-and-go package. The air conditioned cabin has an air seal, minimising the ingress of dust, to protect against damage to the control equipment. The cabin, which is located near the roof of the store also improves safety as technicians are no longer required to operate the system from the crane bridge.

Variable speed drives were also fitted to the Demag crane for smoother travel, reducing bucket sway and minimising the possibility of collision damage to the store’s walls. The variable speed drives also provide greater positioning accuracy when depositing raw material in the store bays.

The crane system’s cross and long travel speeds were increased to improve productivity and accommodate the additional volumes of gypsum and limestone delivered to the plant. Terex also replaced and updated cross and long travel festooned cables, as part of the upgrade.

CEMEX’s Project Team Electrical Co-ordinator, Robin Page, reported that the Demag Service team had delivered a well engineered solution to meet the specific requirements of the refurbishment, improving performance to meet sustained growth.

“The automation and upgrade of the Demag crane system has enhanced our efficiency and production capacity, speeding up the handling of gypsum and limestone. Previously, we often incurred waiting time charges from hauliers, when the material handling system couldn’t keep pace with deliveries, but these have now been eliminated.”

About Terex Material Handling

Terex MHPS GmbH is one of the world’s leading suppliers of crane technology with Demag industrial cranes and crane components. The core competence of the Terex Material Handling business group lies in the development, design and production of technically sophisticated cranes, hoists and components and the provision of sales support and services for these products. Terex Material Handling manufactures at 19 locations on five continents and reaches its customers thanks to its presence in more than 60 countries.

About Terex Corporation

Terex Corporation is a diversified global manufacturer engaged in the mechanical and plant engineering sector. A core activity of Terex Corporation is the provision of reliable, customer-driven solutions for many applications, including the construction, infrastructure, shipping, transportation, quarrying, mining, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms, Construction, Cranes, Material Handling & Port Solutions and Materials Processing. Terex Financial Services offers a wide range of products and services to assist in the acquisition of Terex equipment. Please visit our websites at www.demagcranes.com and www.terex.com for further information.


Helping to build a Great Britain – CEMEX’s vision is to help build a greater Britain by providing solutions to construction problems through its innovative building materials, its expertise, its understanding of the construction issues and its people. CEMEX aims to create the best service and the best solutions for a better future.


CEMEX is a global manufacturer of building materials and the biggest Mexican investor in the UK, with 3,000 people employed across 450 sites nationwide. In this country, CEMEX is a leading provider of aggregates, cement, ready-mixed concrete and rail sleepers with annual sales of around £1 billion.

Email: bnb-help@terex.com · Website: www.demagcranes.co.uk