At Nucor Steel Gallatin in Ghent, Kentucky, Carlisle & Bray Enterprises handles mill services, coil loadout, scrap handling, and recycling operations. As safety requirements evolved and production demands increased, the company began searching for a solution capable of handling heavy steel coils while eliminating personnel exposure during barge loading operations. 

That search ultimately led to the SENNEBOGEN 885 G. 

 Built for a Unique Application 

Carlisle & Bray’s requirements called for a machine capable of placing steel coils weighing up to 50 tons into barges positioned as much as 50 feet below the dock.

Working alongside SENNEBOGEN’s engineering team, the company evaluated the application requirements, including lifting capacity, reach, and working depth. After reviewing the specifications, the SENNEBOGEN 885 proved to be the right fit for the operation.

“The 885 G Max matched up with the work that we were doing,” said Rob Carlisle, President and Co-Owner of Carlisle & Bray Enterprises.

Today, the machine routinely handles finished steel coils destined for the automotive industry, lifting them directly from trailers and placing them into barges in a single cycle.

Redefining Safety on the River 

While lifting capacity was important, safety was the primary driver behind the project. 

Historically, loading coils into barges required personnel to work inside the barge while cranes lowered product into position. Looking to improve safety, Carlisle & Bray worked alongside Nucor and SENNEBOGEN to develop a loading process that could remove personnel from the barge during coil placement. 

“It became a product that we could use where we could get men out of barges while we set coils into it,” Carlisle explained. 

Tony Nath, Vice President of Services at Carlisle & Bray, said the project began with a simple goal: removing employees from a potentially hazardous environment. 

“The biggest thing is safety,” Nath said. “It gave us an opportunity to eliminate that.” 

By combining the reach and precision of the SENNEBOGEN 885 with changes to the loading process, the operation can now load coils without personnel working beneath suspended loads inside the barge. 

Productivity Beyond Traditional Cranes 

In addition to improving safety, the SENNEBOGEN 885 has dramatically increased efficiency throughout the loading process.

According to Nath, traditional cable cranes could require more than a minute to complete a single loading cycle. The 885 reduced that time to approximately 35 seconds.

For operator Dave Brock, the difference is immediately noticeable.

“The maneuverability is second to none,” Brock said. “It just simplifies every aspect of loading coils.”

The machine’s hydraulic controls provide operators with precise control over heavy loads while improving placement accuracy and reducing cycle times.

Under ideal conditions, a barge that once required 10 to 12 hours to load can now be completed in as little as three hours.

One Machine, Multiple Applications 

With grapples, magnets, C-hooks, and D-hooks, the 885 gives Carlisle & Bray more than a coil-loading solution. The machine is used throughout the facility for heavy lifting, truck loading, truck unloading, scrap handling, and barge loading operations, giving the team flexibility as applications change. 

That versatility is already expanding what Carlisle & Bray can move by river. 

“Now we’re seeing an opportunity where we can use the river to handle more finished products,” Carlisle said. 

The result is a machine that supports today’s coil loadout operations while giving the team more flexibility for future material handling needs. 

Designed with the Operator in Mind 

While the 885 was selected for its lifting capabilities, operator comfort remains a key part of its performance. 

“It’s like going to an office and going three stories high and picking 50 tons in the air,” Carlisle said. 

Operator Dave Brock echoed that sentiment, pointing to the machine’s spacious cab, visibility, and quiet operating environment. 

“The cab is enormous,” Brock said. “The machine is running wide open right now, and it’s quiet as a church mouse in here.” 

The combination of comfort, visibility, and hydraulic precision allows operators to work efficiently throughout long shifts while maintaining control over heavy loads. 

A Partnership Built on Support 

For Carlisle & Bray, the relationship with SENNEBOGEN extends far beyond the initial purchase. 

From the initial application discussions and machine assembly to operator familiarization, attachment development, and ongoing support, SENNEBOGEN remained involved throughout the process. 

“It couldn’t have been better,” Carlisle said. 

As the company continued to refine applications and explore additional uses for the machine, SENNEBOGEN worked alongside the team to identify attachment options, troubleshoot challenges, and maximize the machine’s capabilities. 

“The team at SENNEBOGEN was really good about helping us learn a little more about it,” Nath said. 

That collaboration has helped Carlisle & Bray maximize the capabilities of the 885 while positioning the machine for future applications. 

Looking Ahead 

As production demands continue to grow, Carlisle & Bray sees the SENNEBOGEN 885 playing an increasingly important role in future operations. 

The machine’s combination of safety, productivity, versatility, and operator-focused design has allowed the company to rethink how material moves throughout the facility while opening the door for additional applications in the years ahead. 

“It’s done everything that we asked it to do,” Carlisle said. “We got what we asked for.”